Tata_TL_WM.pdf

ii

MAIN INTRODUCTION

All specifications are given in C.G.S. System(Metric System) unless otherwise specified.

Created by :Tata Motors Ltd.CVBU - International Business UnitMumbai

Reproduction or translation of the whole or part of theworkshop manual without our written approval isprohibited.

Subject to modification in Design, Specification andEquipment.

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3) On the left of the screen, you will find bookmarks for all the respective groups.

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5) The bookmarks can be expanded/collapsed by clicking on the tool on the left of thebookmark name.

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iii

MAIN INTRODUCTION

This manual brings to you the technical know-how on maintenance & repairs of TATA Telcolinemodel. This manual is applicable for :

- LHD/RHD versions

- Single cab / Crew cab versions

- Euro II / Euro III versions

- 4x2 & 4x4 versions

Assuming that the workman is fully conversant with general automobile repair practices, repairprocedures outlined in this manual emphasize special aspects of the product.

This manual is divided into 20 groups.

Information on technical specifications, tightening torque, special tools, disassembly/inspection/assembly procedures with the help of special tools & trouble shooting procedure etc. whereverneeded have been furnished in all groups.

Procedure for repair of proprietary aggregates as given by respective manufacturers also havebeen included to make this manual comprehensive.

Appropriate symbols have been provided at top corner of each page.

A section has been included at the end to give details of important product modificationsintroduced on facelift version.

All data contained in this manual is based on the latest product information available at thetime of publication.

The contents are not binding on us, are subject to change without notice and are for illustrativepurpose only.

For any further technical advice or clarifications please get in touch with :

Tata Motors Ltd.Commercial Vehicles Business Unit,International Business,Shivsagar Estate, Block-A,Dr. Annie Besant Road,Worli, Mumbai - 400 018.India.

v

MAIN INTRODUCTION

GENERAL

GROUP INDEX

GENGINE (4DLTC)

CLUTCH

GEAR BOX

TRANSFER CASE

ACCELERATOR

SUSPENSION

FRONT AXLE 4X2

FRONT LIVE AXLE 4X4

REAR AXLE

WHEELS & TYRE

PROPELLER SHAFT

BRAKES

POWER STEERING

FUEL SYSTEM

EXHAUST SYSTEM

RADIATOR

ELECTRICALS

CAB/LOAD BODY

AIR CONDITIONING

PRODUCT IMPROVEMENTS

1

GENERAL

GENERAL

3

GENERAL

INTRODUCTION

This manual provides information on chassis andaggregate numbering system, location of aggregatenumbers, broad technical specifications and fillingcapacities.

It also provides information on fuel, coolant andlubricants specified, tightening torque values andservice schedule chart.

Lubrication and maintenance work needs to becarried out as given in service schedule chart.

i

5

GENERAL

CONTENTS

Sr. No. Description Page No.

1. Good workshop practices & safety precautions 07

2. Chassis Type Designation

Euro II versions 10

Euro III versions 12

2. Chassis Numbering System

2A. Export Vehicles RHD 13

2B. Export Vehicles LHD 14

2C. CKD Vehicles RHD 15

2D. CKD Vehicles LHD 15

3. Aggregate Numbering System & Location of Serial Number

3A. Frame 16

3B. Engine 17

3C. Gear Box 18

3D. Transfer Case 18

3E. Rear Axle (Tata Motors) 19

3F. Rear Axle (Dana Spicer) 19

3G. Front Live Axle (Dana Spicer) 20

3H. Power Steering Gear Box (Rane) 20

3I. Power Steering Gear Box (ZF) 20

3J. Cabin 21

3K. Load Body 21

3L. Crown Wheel & Tail Pinion Set (Tata Motors) 22

4. Technical Specifications 23

5. Fuel, Lubricants & Coolants

5A. Fuel 27

5B. Lubricants 27

5C. Coolants 28

5D. Filling capacities at a glance 29

6. Lubrication & Maintenance

6A. Lubrication points (For 4x2) 30

6B. Lubrication points (For 4x4) 31

6C. Tightening Torque 32

6D. Service Schedule Chart 33

7

GENERAL

GOOD WORKSHOP PRACTICES &SAFETY PRECAUTIONS

Following are some safety precautions to be observedin the workshop.

● Always ensure that all the repair / maintenancework carried out should be as per the instructionsprovided in the workshop manual.

● Use protective clothing, apron, hand gloves, andsafety shoes while working in the workshop. Donot wear watch, rings and belt while serving thevehicle.

● Keep your work area, equipment and tools cleanat all times.

● Make sure you use the proper tool for the job anduse it the rightway. The improper tool or its incorrectuse can damage the part you are working on orcause injury or both.

● Never keep the tools on the floor/vehicle. The toolsshould be kept in the tool box after use.

● Cover fenders, seats, steering wheel and any otherparts those are likely to get scratched/soiled beforestarting any service work (Fig. 1).

● While servicing the vehicle in engine runningcondition make sure that the gear shifting lever isin neutral position and parking brake is fully applied.Never run the engine without proper ventilation andadequate means of getting rid of exhaust gases.

● Prior to removing or disassembling parts, theymust be inspected carefully to isolate the causefor which the service is called for (Fig. 2).

● All the reusable dismantled components must bekept in a clean enamel coated white traysequentially in an orderly manner to facilitate theiraccurate and proper reinstallation (Fig. 3).

● Never reuse the parts like oil seals, gaskets,packing, O-rings, locking washers, split pins, selflocking nuts and certain other parts.

● Plug the ports / openings of aggregates such asFIP / Injectors, Turbocharger, Intercooler, Radiator,Fuel high pressure lines, Air/vaccum/oil pipes,TMC, etc., whenever removed from vehicle.

Fig. 2

Fig. 1

Fig. 3

8

GENERAL

Fig. 4

Fig. 5

● For correct reinstallation of EGR system hosesattach a tag describing the correct positionsFig. 4.

● Make sure only the branded lubricants, coolant,corrosion protection coatings and sealants areused.

● Check all the lines for leaks related to the systemslike fuel, oil, coolant, vacuum, exhaust and brakesafter servicing Fig. 5.

● Do not disconnect the fuel line between the injectorand the fuel pump without releasing the fuelpressure or fuel can be sprayed out under pressure.

Precaution for Catalytic Converter Fig. 6.

Caution : If large amount of unburnt fuel goes intothe converter, it may overheat and creat a firehazard. To prevent this, observe the followingprecautions.

● Use only Low sulphur (<0.25%) Diesel.

● Engine compression checks should be carried outwithin the shortest possible time.

● Do not run the engine when the fuel tank is nearlyempty to avoid engine misfire and damage tocatalytic converter.

Fig. 6

VS

V to

EG

R valve

Boost controller

backleak

9

GENERAL

Precaution for Electrical circuit service :

● Disconnect the negative cable of the battery whileservicing the electrical parts that do not requirebattery power Fig. 7.

● While removing the battery first disconnect thenegative cable and then the positive cable. Whilereinstalling the battery, first connect the positivecable and then negative cable.

Fig. 8

Fig. 9

Fig. 7

● Be sure to turn the ignition switch off beforedisconnecting and connecting coupler to avoidelectronic parts damage Fig. 8.

● Do not touch the electrical terminals of parts whichuse microcomputers (e.g. electronic control unitslike ECM etc.) to avoid damage to these partsfrom static electricity from your body Fig. 8.

● Always use the correct voltmeter, ohmmeter fortaking measurement to avoid damage to theelectronic control unit and sensors.

● Make sure to insert the probe from wire harnessside of the connector for taking measurement.

● Make sure the connector halves are mating properlyand terminals seating precisely in the connectorbody Fig. 9.

10

GENERAL

374 021 207/28 Normal Control Chassis with Cab & Load Body, Pick-up Version, 483 DL TCIC Euro-II Engine with A.C. +Heating & Demisting, 2825mm W.B.

374 023 207/28 - 4x4 Normal Control Chassis with Cab & Load Body, 4x4Pick-up Version with 483 DL TCIC Euro-II Engine withHeating & Demisting, 2825mm W.B.

374 024 207/28 Normal Control Chassis with Cab & Load Body, Pick-up Version with 483 DL TCIC Euro-II Engine withHeating & Demisting, 2825mm W.B.

374 026 207/31 Normal Control Chassis with Cab & without Load Bodywith 483 DL TCIC Euro-II Engine with Heating &Demisting, 3150mm W.B.

374 027 207/28 Normal Control Chassis with Cab & Load Body, 4x4Pick-up Version with 483 DL TCIC Euro-II Engine withA.C. + Heating & Demisting, 2825mm W.B.

374 030 207/28 Normal Control Chassis with Cab & without Load Body4x4 Pick-up Version with 483 DL TCIC Euro-IIEngine with A.C. + Heating & Demisting, 2825mm W.B.

374 054 207/31 Normal Control Chassis with Crew Cab & Load Body,Pick-up Version, 483DL TCIC Euro-II Engine, A.C. +Heating & Demisting, 3150mm W.B.

374 057 207/31 Normal Control Chassis with Crew Cab - 4 x 4 & LoadBody, Pick-up Version, 483DL TCIC Euro-II Engine,A.C. + Heating & Demisting, 3150mm W.B.

374 067 207/31 Normal Control Chassis with Crew Cab & Load Body,Pick-up Version, 483DL TCIC Euro-II Engine withHeating & Demisting, 3150mm W.B.

374 068 207/31 Normal Control Chassis with Crew Cab & Load Body,4x4 Pick-up Version, 483DL TCIC Euro-II Engine withHeating & Demisting, 3150mm W.B.

Telcoline

Telcoline-Tdi-4x4

Telcoline-Tdi

Telcoline-Tdi

Telcoline-Tdi-4x4

TelcolineCrew Cab-Tdi

TelcolineCrew Cab-Tdi 4x4

Telcoline-Tdi-4x4

TelcolineCrew cab

TelcolineCrew cab-

Tdi-4x4

1. CHASSIS TYPE DESIGNATION

TELCOLINE EURO - II

Chassis Sales Designation DescriptionType No. Export

11

GENERAL

Telcoline-Tdi-4x4

Telcoline-P

TelcolineCrew Cab-P

TelcolineCrew Cab-P

4x4

Telcoline-P4x4

TELCOLINE EURO - II


374 084 207/31 Normal Control Chassis with Cab - 4x4, Without LoadBody, 483 DL TCIC Euro-II Engine with A.C. + Heating& Demisting, 3150mm W.B.

374 151 207/28 Normal Control Chassis with Cab & Load Body, Pick-up Version with 486 PL Euro-II Engine with Heating &Demisting, 2825mm W.B.

374 185 207/31 Normal Control Chassis with Crew Cab & Load Body,Pick-up Version with 486 PL Euro-II Engine with AC,Heating & Demisting, 3150mm W.B.

374 186 207/31 Normal Control Chassis with Crew Cab 4x4 & LoadBody, Pick-up Version with 486 PL Euro-II Engine withAC, Heating & Demisting, 3150mm W.B.

374 250 207/28 Normal Control Chassis with Cab & Load Body 4x4Pick-up Version with 483 PL Euro-II Engine with A.C.+ Heating & Demisting, 2825mm W.B.

12

GENERAL

374 501 Telcoline Normal control chassis with cab & load body, pick-upversion, 483DL TCIC Euro-III Engine, Heating &Demisting 2825 mm W.B.

374 502 Telcoline Normal control chassis with cab & without load bodypick-up version, 483DL TCIC Euro-III Engine, Heating& Demisting, 3150mm W.B.

374 504 Telcoline Normal control chassis with cab & load body, pick-upversion, 483DL TCIC Euro-III Engine, A.C. + Heating& Demisting, 2825mm W.B.

374 531 Telcoline Normal control chassis with cab & load body - 4x4,pick-up version, 483DL TCIC Euro-III Engine, Heating& Demisting, 2825mm W.B.

374 534 Telcoline Normal control chassis with cab & with load body -4x4, pick-up version, 483DL TCIC Euro-III Engine,A.C. + Heating & Demisting, 2825mm W.B.

374 551 Telcoline Normal control chassis with crew cab & load body,pick-up version, 483DL TCIC Euro-III Engine, Heating& Demisting, 3150mm W.B.

374 552 Telcoline Normal control chassis with crew cab & load body,pick-up version, 483DL TCIC Euro-III Engine, A.C. +Heating & Demisting, 3150mm W.B.

374 581 Telcoline Normal control chassis with crew cab, & load body -4x4 pick-up version, 483DL TCIC Euro-III Engine,Heating & Demisting, 3150mm W.B.

374 582 Telcoline Normal control chassis with crew cab, & load body -4x4, pick-up version, 483DL TCIC Euro-III Engine,A.C. + Heating & Demisting, 3150mm W.B.

Tdi

Tdi

Tdi

Tdi-4x4

Tdi-4x4

Crew cabTdi

Crew cabTdi

Crew cabTdi-4x4


1. CHASSIS TYPE DESIGNATION

TELCOLINE EURO - III

Crew cabTdi-4x4

13

GENERAL

2A. EXPORT VEHICLES (RHD) :

Chassis number is punched at the front on LH long member in a single line without any gap.Chassis number consists of 17 digits as given below :

MAT XXXXXX XXXXX

Indicates producedin Tata Motors Ltd., India.

Year of ProductionYear Code

1-1-1997 to 31-12-1997 - V1-1-1998 to 31-12-1998 - W1-1-1999 to 31-12-1999 - X1-1-2000 to 31-12-2000 - Y1-1-2001 to 31-12-2001 - 11-1-2002 to 31-12-2002 - 21-1-2003 to 31-12-2003 - 31-1-2004 to 31-12-2004 - 41-1-2005 to 31-12-2005 - 5

Plant location

9 For J Block, PuneFirst assembly line

N For J Block, PuneSecond assembly line

Serial No. to start everyyear with 00001 on firstJanuary at each plantlocation.

Drive Type - RHDChassis Type No.(Model, execution, wheel base etc.)

Example : MAT374052V9R25340 indicates Telcoline crew cab normal control chassis with crew caband load body, pickup version with 483 DL TCIC engine, heating & demisting 3150 mmW.B. produced between 1st January 1997 & 31st December 1997, in 'J' Block, Pune,Right hand drive vehicle for export and the serial number of vehicle is 25340.

2. CHASSIS NUMBERING SYSTEM

X X R

14

GENERAL

2B. EXPORT VEHICLES (LHD) :

Chassis number is punched at the front on RH long member in a single line without any gap.Chassis number consists of 17 digits as given below :

MAT XXXXXX X X L XXXXX

Indicates producedin Tata Motors, India.

Chassis Type No.(Model, execution, wheel base etc.)

Year of ProductionYear Code

1-1-1997 to 30-06-1997 - V1-7-1997 to 30-06-1998 - W1-7-1998 to 30-06-1999 - X1-7-1999 to 30-06-2000 - Y

1-7-2000 to 31-05-2001 - 11-6-2001 to 31-05-2002 - 21-6-2002 to 31-05-2003 - 31-6-2003 to 31-05-2004 - 41-6-2004 to 31-05-2005 - 5

Plant location

9 For J Block, PuneFirst assembly line

N For J Block, PuneSecond assembly line

Serial no. to start everyyear with 00001 on firstJune at each plant location(separate sequence).

Drive Type - LHD

Example : MAT374052W9L00750 indicates Tata Telcoline crew cab normal control chassis with crewcab and load body, pick-up version with 483 DL TCIC engine, heating & demisting 3150mm, W.B. produced between 1st July, 1997 and 30th June, 1998 in 'J' Block, Pune, Lefthand drive vehicle for export and the serial number of vehicle is 00750.

15

GENERAL

2C. CKD VEHICLES (RHD) :

XXXXXX X 5 R X XXXX

Chassis Type No.(Model, execution,wheel base etc.)

Year of production asgiven in clause "Export Veh. - RHD". Plant location

7 For Veh. produced at Pune

Serial no. to start every yearwith 0001 on first January ateach plant location.

For CKD Vehicles

Drive type R - RHD

2D. CKD VEHICLES (LHD) :

XXXXXX X 5 L X XXXX

Chassis Type No.(Model, execution,wheel base etc.)

Year of production asgiven in clause "Export Veh. - LHD". Plant location

7 For Veh. produced at Pune

Serial no. to start every yearwith 0001 on first June ateach plant location.

For CKD Vehicles

Drive type L - LHD

16

GENERAL

3. AGGREGATE NUMBERING SYSTEMAND LOCATION OF SERIAL NUMBER

3A. FRAME

1 The frame no. is punched on RHlong member at rear end.

2 'L' is to be punched for LHDexecution after 1st two barrels eg.B002L TQ 5 81650.

Frame is numbered in five barrels as below :

Example : X XXX XX X XXXXX––– ––––– ––– ––– –––––––1 2 3 4 5

Barrel 1 : Basic modelT - 207 family

Barrel 2 : Variation in basic model and wheelbase :

004 - 2825 mm W.B., Pickup, 4PL005 - 2825 mm W.B., Pickup006 - 2825 mm W.B., Pickup with

crew cab007 - 2825 mm W.B., Passenger

version with crew cab013 - 2825 mm W.B., Pick-up 4x4

version050 - 3150 mm W.B., Pick-up

version with Crew cab051 - 3150 mm W.B., Tata Mobile

pick-up version063 - 3150 mm W.B., Pick-up with

Crew cab, 4x4 version

Barrel 3 : Year of Production

SQ - 1997RQ - 1998QQ - 1999ZZ - 2000YZ - 2001XZ - 2002WZ - 2003VZ - 2004UZ - 2005

Barrel 4 : Plant Location

8 Pune - 'J' Block

Barrel 5 : Cumulative Serial No. of framecommencing from 00001 on 1stJanuary, every year.

Fig. 1 - Location of chassis number plate on cab

Fig. 2 - Chassis number plate on long member

17

GENERAL

Fig. 3 - Location of engine number plate

3B. ENGINE

Engine is numbered in seven barrels eachas below :

Example :

XXXXXXX XX X X XX X XXXXX–––––––––– ––– –– –– ––– –– ––––––

1 2 3 4 5 6 7

Barrel 1 : Indicates engine model ex. 483 DLTC

Barrel 2 : Indicates variation in basic model ofengine ex.

55 - 483DL turbocharged, Iner-cooled diesel engine, 64kW@4300rpm, linered, meetingEuro-III emission norms withcatalytic convertor & ExhaustGas Recirculation (EGR)

Barrel 3 : Indicates 'L' for LHD application only.

Barrel 4 : Indicates month of Production :

Month Code Month Code

January A July G

February B August H

March C Sept. J

April D Oct. K

May E Nov. L

June F Dec. M

Barrel 5 : Indicates Year of Production (Same asmentioned above for 'Frame'.

Barrel 6 : Indicates Plant Location7 & 8 for 'D' block, Pune

Barrel 7 : Sr. No. starting from 00001 on 1stJan. every year.

18

GENERAL

3C. GEAR BOX

Gear box is numbered in five barrels eachas below :

Example : XXXX XXX XX X XXXXX–––––– –––– ––– ––– ––––––

1 2 3 4 5

Barrel 1 : Indicates the basic model numberedas follows :

2684 - G-76 Gearbox2684 D - G-76 Gearbox with dual

synchro cones

Barrel 2 : First digit indicates types of geararrangement and shift7 - For synchromesh - semi-remote8 - For synchromesh - full-remote

Second digit Indicates vehicle type1 - For normal control vehicle

Third digit indicates 1st gear ratiofor G-76 gear box0 - For first gear ratio 3.87 (std.)1 - For first gear ratio 3.87 with

modified 2nd gear ratio 2.362 - For first gear ratio 4.1

Barrel 3 : Indicates Year of Production(As explained in Frame NumberingSystem.)

Fig. 4 - Gear box number location

Barrel 4 : Indicates Plant Location

Plant Location Plant Code'D' block, Pune 5 and 6

6 is to be used if serial no. reachesupto 99,999 under plant code 5 in thesame year.

Barrel 5 : Indicates Cumulative Serial No. as perframe.

Note : Gear box for LHD vehicle will havean additional letter 'L' punched afterfirst two barrels.

Fig. 5 - Transfer Case number location

3D. TRANSFER CASE

Identification tag is attached to the transfercase at location shown in figure.Manufacturing details are stamped on tag. Thisinformation is necessary for orderingreplacement spare parts.

19

GENERAL

Fig. 6 - Number location on rear axle (Tata Motors)

3E. REAR AXLE (TATA MOTORS)

Rear axle is numbered in five barrels asbelow :

Example : XXX XX(X) XX X XXXXX–––– ––––– ––– ––– ––––––

1 2 3 4 5

Barrel 1 : Indicates the basic modelnumbered as follows :

371 - For 207 family vehicles

Barrel 2 : Indicates variation in basic model :

01 - For RAS 101 single tyre,salisbury type for pick-upwith leaf spring suspension.

Barrel 4 : Indicates Plant Location

Plant Location Plant Code

'D' Block 5

'H-4' Block 6

'H-6' Block 8

Barrel 3 & 5 : (As explained in Frame NumberingSystem.)

Fig. 7 - Dana Rear axle number location

3F. REAR AXLE (DANA SPICER)

Rear axle is numbered in three barrels asbelow :

Example : X XXX XXX–––– ––––– –––

1 2 3

Barrel 1 : Indicates the year of manufacture.

6 - Manufacturing year 1996

Barrel 2 : Represents the day ofmanufacturing year.

215 - 215th day of 1996

Barrel 3 : Represents the serial number ofaxle produced on the day.

034 - 34th axle produced on 215thday of 1996

20

GENERAL

Fig. 8 - Live Front axle number location

3G. FRONT LIVE AXLE (DANA SPICER) :

Front live axle is numbered in three barrelsas below :

Example : X XXX XXX–––– ––––– –––

1 2 3

Barrel 1 : Indicates the year of manufacture.

6 - Manufacturing year 1996

Barrel 2 : Represents the day ofmanufacturing year.

215 - 215th day of 1996

Barrel 3 : Represents the serial number ofaxle produced on the day.

034 - 34th axle produced on 215thday of 1996

3H. POWER STEERING GEAR BOX :(RANE)

Example : 1XX9999

1 - Stands for the type of gear and in this casethe Type 54 gear

X - First X stands for year of manufacture. 1990- A, 91 - B, 92 - C, 93 - D, 94 - E, 95 - F, 96- G, 97 - H, 98 - J, 99 - K, 2000 - L, 01 - M,02 - N, 03 - P, 04 - Q, 05 - R, 06- S, 07 - T,08 - U, 09 - V

X - Second X stands for Month of manufac-ture - Jan - A, Feb - B, Mar - C, Apr - D,May - E, June - F, July - G, Aug - H,Sep - J, Oct - K, Nov - L, Dec - M.

9999 - Stands of the serial number of the gear dur-ing the financial year.

Fig. 9 - Number location on steering gear box(Rane)

21

GENERAL

3J. CABIN

Drivers cab is numbered in five barrels asbelow :

Example : X(X) XXX XX X XXXXX––––– –––– –––– ––– ––––––

1 2 3 4 5

Barrel 1 : Indicates the basic model of cab

NC - Crew cab, normal controlP - Tata mobile normal control

Barrel 2 : Indicates vehicle model of Cab

371 - For Telcoline model

Barrel 3 : (As explained in Frame NumberingSystem.)

Fig. 11 - Number plate location on body4 & 5

3I. POWER STEERING GEAR BOX : (ZF)

It is numbered in five barrels as per examplegiven below :

Example : M033 955 805 1000 01/03––––– –––– –––– ––– ––––––

1 2 3 4 5

Barrel 1 : Indicates the vehicle model

Telcoline / Multi Utility Vehicle

Barrel 2 : Indicates type of steering gearassembly.

Barrel 3 : Indicates design serial number ofsteering gear assembly.805 for Telcoline facelift RHD802 for Telcoline facelift LHD

Barrel 4 : Indicates gear box serial numberproduced in the year.

Barrel 3 : Indicates month & year of production.01 - January03 - Year 2003

Fig. 9 - Number location on steering gear box (ZF)

22

GENERAL

3K. CROWN WHEEL AND TAIL PINIONSET (Tata Motors)

Crown wheel and Tail pinion set is numberedin five barrels each as below :

Example : XX XXXXX(X) XX X XXXXX––– ––––––––– –––– ––– ––––––1 2 3 4 5

Barrel 1 : Indicates type and form of gear teethof crown wheel and tail pinion set

RS - For Oerlikon type Spiral gear

RH - For Oerlikon type Hypoid gear

GS - For Gleason type Spiral gear

GH - For Gleason type Hypoid gear

Barrel 2 : Indicates exact mounting distance inmm. of the pinion from the centrelineof the crown wheel as found afterlapping and to be maintained duringassembly.

Barrel 3, : (As explained in Frame Numbering4 & 5 System.)

Fig. 8 - Number location on crown wheel and tailpinion set

23

GENERAL

ENGINEModel : TATA 483DL TCType : Water Cooled Indirect Injection

Turbo Charged IntercooledDiesel Engine with Crank CaseBreather & Oil Separator

No. Of Cylinders : 4 InlineBore / Stroke : 83 mm x 90 mmCapacity : 1948 ccMax. Engine Output : 64 kw (90 ps) at 4300 rpmMax. Torque : 190 Nm (19 kgm)

at 2000-3000 rpmCompression Ratio : 21 : 1Firing Order : 1 - 3 - 4 - 2Air Filter : Dry (Paper) TypeOil Filter : Spin-on Full Flow Paper TypeFuel Filter : Two Stage, Fine FiltrationFuel Injection Pump : Rotary Type with Electric Stop

SolenoidGovernor : MechanicalEngine Oil Capacity : Max. 7.7 litres / Min. 5.7 litresWeight Of Engine : 220 kg (Dry)Radiator Frontal Area : 2340 sq. cmExhaust System : Exhaust gas recirculation

(Euro III), catalytic convertor(Euro II & III)

CLUTCH: Single Plate Dry Friction

Diaphragm TypeOutside diameter of : 228 mmclutch lining.Friction Area : 463 sq.cm (Approx.)

GEAR BOXModel : G 76 - 5/3.87 with Overdrive

(Inline shifting)No. of gears : 5 Forward 1 Reverse,

Synchromesh on all gearsGear Ratios : 1st - 3.87

2nd - 2.223rd - 1.374th - 1.005th - 0.82Rev - 3.42

TRANSFER CASE ( For 4x4 version only)

: With Electrical Shift

Arrangement

Mounted on Gear Box with

Electronic Controller Unit.

Drive Options : 4x2 - Ratio 1:1

4x4 High - Ratio 1:1

4x4 Low - Ratio 1:2.48

REAR AXLE4 x 2 (Non Facelift) : Single Reduction,

Salisbury Type

Rear Axle with Hypoid Gears,

Semi-Floating Axle Shafts.

4 x 4 (Non Facelift) : As above but with limited

Slip differential.

4x2 & 4x4 (Facelift) : Limited slip differential fitment

100%

Ratio : 4.88 (44/9)

FRONT AXLE ( For 4x2 version)

: Independently suspended.

FRONT AXLE (For 4x4 version)

Independently Suspended with

Automatic Hub Locks.

Ratio : 4.88 (44/9)

POWER STEERINGType : Hydraulic Power

Assistance

Ratio : 18.2 : 1 (RANE),

18.9 : 1 (ZF)

Steering Wheel : 380 mm dia, 4 spoke

Steering column : Provided with tilt mechanism for

height adjustment.

BRAKESService Brakes : Vacuum assisted independent

hydraulic brakes on front and

rear wheels through tandem

master cylinder. Vacuum pump

mounted on alternator

Front Brakes : 271 dia Disc brake

Rear Brakes : 282 dia Drum brake

TECHNICAL SPECIFICATIONS :

24

GENERAL

Parking Brakes : Cable operated linkages

Mechanical acting on rear wheels

LCRV : Provided for rear brakes

FRAME: Ladder type cranked frame with

boxed section long members &

Welded Cross Members.

Depth : 110 mm (max.)

Width : 60 mm

Tow Hooks : At Front & Rear.

SUSPENSIONFront : Double Wishbone Type with

Torsion Bar

Rear : Parabolic Leaf Springs

Shock Absorber : Hydraulic Double Acting

Telescopic Type at Front

and Rear

Antiroll Bar : At Front and rear

WHEELS AND TYRESTyres : 205/80 R 16 (Tubeless radial)

Rib pattern on 4x2

Block pattern on 4x4

Wheel Rims : 5.5 J x 16 Steel Rims

Wheel Caps : Standard

No. of Wheels : Front-2 Rear-2 Spare-1

FUEL TANK: Made out of steel sheets

Capacity : 60 litres (Single Cab)

50 liters (Dual Cab)

CABType : Normal Control All Steel Shell

Seats : With foam laminated fabric

Front Seat Option I : Bucket Seats with front to rear

adjustment, backrest adjustment,

adjustable head rest & seat belts

Option II : Bench seat with front to rear

adjustment, seat belts & head

rests (adjustable)

Rear Seat : Non adjustable bench seat with

(for Dual Cab) seat belts, lap belt for middle

occupant & with neck rests

Windshield : Laminated & Tinted with Darker

built in Green Tint Band at Top

Door window glass : Tinted - AC with heating/

demisting

Plain - Heating/demisting

Ventilation Option I : Air Conditioning with Heating /

Demisting

Option II : Heating / Demisting

Mirrors : LH/RH Side External Rear View

Mirrors adjustable from inside &

Inner Antiglare Rear View Mirror

Rear glass : Plain fixed glass with electrical

demisting.

Other Features : 1. Soft Feel Dashboard /

console

2. Moulded Roof Linings

3. Central Locking

4. Cab Guard on Load Body

5. Provision for fixing canopy

on load body

6. Moulded Carpets

7. Sun Visors with Plastic

Moulded Stem

8. Vanity mirror on sun visor

(Co-driver side)

9. Magazine Pockets

10. Ash Tray & Cigarette

Lighter

ELECTRICAL SYSTEMSystem Voltage : 12 Volts (-ve earth)

Alternator Capacity : 65 Amps for heating/demisting

75 Amps for AC with

heating/demisting

Battery : 12 V, MF 70Z

(75 Ah, 20 Hr rating)

25

GENERAL

Wind Screen Wiper & : 2 Speed with Intermittent Wiping,

Washer Spoiler on Driver Side Wiper

blade, 2.5 lit. Windscreen

Washer Water Reservoir

Steering Lock cum : Standard Fitment

Ignition Switch

Instruments : a) Speedometer (km/hr) and

Odometer (km) & Trip

meter (km)

b) Fuel Gauge with Low Fuel

Indicator

c) Water Temperature Gauge

d) Engine RPM meter

Indicator Lamps : For Battery Charging, Low Oil

Pressure, Rear fog lamp,

Hand Brake + Brake Fluid Level,

Direction Indicator, Main Beam,

Glow Plug Timer & Hazard

Warning.

4x4 High and 4x4 low indication.

(for 4x4 version only),

trailer attachment (optional)

Combi Switch : With Self Cancelling Turn Signals

and Hazard Warning Switch

Tail Lamp : Four Function Tail Lamp &

Separate Reflex Reflector at

Rear.

Head Lamp : Semi-Sealed European Beam

Asymmetrical Pattern with

Halogen bulb. Built-in front

Parking Light

Other Electrical : 1. Rear Fog LampFitments 2. Blinkers on Side Bonnet

3. Roof Lamp (2 nos. for dualcab)

4. Provision for Radio/CassettePlayer/Speakers

5. Trip meter6. Reading lamp7. Chime unit / buzzer8. Door Reflex Reflector

Stickers

9. Rear Number Plate Lamps10. Head lamp levelling device11. Rear glass heating/

demisting12. Provision for digital clock

fitmentOptional fitments : 1. Speedometer with miles/hr

Primary & km/hr SecondaryScale & Odometer in miles

2. Immobilizer (anti theftdevice)

3. Provision for trailerattachment indication ondash board

4. Over speed warning device

PERFORMANCE

Parameter 4x2 4x4

Max. speed at rated GVW

Max gradeability at ratedGVW

123 kmph(76 mph)

123 kmph(76 mph)

33% 72%(4x4 low)

SPECIFICATIONS OF HEATING, VENTILATION &AC SYSTEM :

PARAMETER VALUE

COOLING CAPACITY 3080 ±310 kcal/hr

at 280 ±28 m3/hr

AIR FLOW AMOUNT 400 m3/hr

RATED VOLTAGE 13.5 V

ELECTRIC CONSUMPTION 376 W

BLOWER MOTOR 216 ±21w

MAGNETIC CLUTCH 40 W

COND. FAN MOTOR 120 W

EVAPORATOR 311 x 185 x 85 mm

CONDENSER (SERPENTINE) 330 x 490 x 22 mm

COMPRESSOR TYPE 10 P13 (133.6 CC/rev.)

REFRIGERANT TYPE R 134a

QUANTITY - 670 ± 20

grams

LUBRICATING OIL DENSOIL - ND8

Quantity - 80 ± 20 c.c.

26

GENERAL

Wheel Base 2825 3150 3150 2825 2825 3150Track front 1511 1511 1511 1511 1511 1511Track Rear 1461 1461 1461 1461 1461 1461Overall Length 4585 4955 4910 4585 4630 4910Max. Width 1810 1810 1810 1810 1810 1810Front Overhang 810 810 810 810 810 810Rear Overhang 950 995 950 950 995 950Overall height Unladen 1755 1755 1755 1755 1755 1755Overall height Laden 1720 1720 1720 1720 1720 1720Min. turning cicle dia 12600 15000 15000 12600 12600 15000Min. turning circle 13500 16100 16100 13500 13500 16100clearance circle diaGround clearance (Laden) 200 200 200 200 200 200

MAIN CHASSISDIMENSIONS AS PER

ISO:612 in mm (Nominal)(TOLERANCES AS PERINTER EUROPE STVZO)

4x2Single Cab Dual Cab

Withloadbody

Without loadbody


Withloadbody

Without loadbody

With loadbody

With loadbody

Gross vehicle weight 2950 2950 2950 2950 2950 2950Max. permissible FAW 1120 1120 1120 1250 1250 1250Max. permissible RAW 1850 1850 1850 1750 1750 1750Complete vehicle kerb 1640 1520 1700 1780 1630 1920weight as per ISO:1176(with spare wheel & tools)Gross combination weight 4950 4950 4950 4950 4950 4950with trailerMax. Mass of Unbraked 750 750 750 750 750 750trailer

WEIGHTS (kg)(TOLERANCE AS PER

INTEREUROPE STVZO)


Withloadbody

Without loadbody

With loadbody


Withloadbody

Without loadbody

With loadbody

LOAD BODYDIMENSIONS

4x2

Single Cab Dual Cab

4x4

Single Cab Dual Cab

Type Pick up type with all steel, Non-integral load body. 90 degree Hinged (wire ropes).Rear tail gate with latch and handle at centre. Provision for fixing canopy.

Wheel Base (mm) 2825 3150 2825 3150

Net Inside loading space 1.88 x 1.41 x 0.4 1.5 x 1.41 x 0.4 1.88 x 1.41 x 0.4 1.5 x 1.41 x 0.4in metres(length x widhth x height)

CHASIS DIMENSIONS / WEIGHTS / LOAD BODY DIMENSIONS

27

GENERAL

Fuel

High speed diesel conforming to IS 1460 or DIN 51601or equivalent is recommended to be used as fuel.

At very low temperatures fluidity of diesel may becomeinsufficient due to paraffin separation. It is therefore,necessary to mix supplementary fuel with summer orwinter grade diesel. Supplementary fuel to be used iskerosene or aviation turbine fuel.

Ratios for mixing of supplementary fuel and dieselare shown in tables given below :

Care should be taken that diesel and supplementaryfuel are thoroughly mixed before filling.

Recommended fuel specification for Euro II &Euro III engines :

Engine oilUse engine oil conforming to API CF4 + or equivalentspecifications as given below :

Ambient temperature 0C Engine oil grade

-10 and Above SAE 15W40-20 to 0 SAE 10W30-10 and Below SAE 5W20

Rear axle oil and live front axle oil (DANA Spicer)Use multigrade oil conforming to SAE 85W140 APIGL5 specifications.

* Friction modifier 40819 (2-5%) to be added to oil forrear axle with limited slip differential.

Rear axle oil (Tata Motors)Use multigrade oil conforming to SAE 85W140 gradeand API GL5 specifications with 6.3% by weight A-99additives.

Gear box oilUse synthetic oil conforming to SAE 75W90 API GL4specifications. If synthetic oil is not available SAE80W90 API GL4 with 7% anglamol additives also canbe used but with lesser drain period.

Transfer case oilUse multigrade oil conforming to ATF to GeneralMotors, Type A, Suffix A specifications.

Power Steering oilUse power steering oil conforming to DEXRON-II Dspecifications OR multigrade oil conforming to ATF toGM Type A, Suffix A specifications.

Chassis & Wheel Bearing Grease (Spicer Axle)Use SS 6805 bearing grease.

CV Joints for Front live axle (Spicer)Use grease M-2001 (Lithium complex grease no. 2 ofCastrol)

Brake and clutch fluidUse brake & clutch fluid conforming to SAE J 1703,DOT 4.

Spicer propeller shaft (where applicable)Lubricate slip joint with NLGI-2 grade grease

Please use only recommended grade of oils for troublefree performance.

Oil change periods recommended in maintenanceschedule should be adhered to.

Use of reclaimed oil is not recommended.

Upto 0 100 0

0 to - 10 70 30

-10 to -15 50 50

Ambienttemperature

upto 0C

Percentage

Summergrade diesel

Supplementaryfuel

Upto -15 100 0

-15 to -20 70 30

-20 and Below 50 50

Ambienttemperature

upto 0C

Percentage

Wintergrade diesel

Supplementaryfuel

Sl.No.

Parameter Unit Emission Norms

EURO III EURO II

1. Cetane number CN 51 48(Min)

2. Sulphur content mg/kg 350 500

3. Lubricity (HFRR) microns 460 460

LubricantsRecommended lubricants conform to the followingspecifications :

FUEL, LUBRICANTS & COOLANT :

28

GENERAL

Coolant

Use coolant as per class II, JIS K2234 with soft wateras per ratio specified below.

Ambient Temperature coolant/water ratio

Below - 18Oc 60:40

-18Oc and above 50:50

Windscreen Washer Antifrost

Make : Antifrost - K

Concentration : 1:5 for 00C(antifrost : water) 1:1 for - 100C

2:1 for - 160C1:0 for -370C

Aggregates filling capacity :

1. Engine oil (Turbocharged engine) : 7.7 Ltr.

2. Gear box G 76 : 1.6 Ltr.

3. Rear axle (Tata Motors) : 1.9 Ltr.

4. Rear axle (spicer) : 2.2 Ltr.

5. Front live axle (spicer) : 1.2 Ltr.

6. Transfer case :1.2 Ltr.

7. Power steering system - Rane : 1.4 Ltr.Power steering system - ZF : 1.6 Ltr.

8. Brake hydraulic system : 0.5 Ltr.

9. Clutch hydraulic system : 0.2 Ltr.

10. Grease : Front axle per hub (Tata Motors): 100 gm.

Rear axle per hub (Tata Motors) : 120 gm.

Front live axle per hub (spicer) : 92 gm.

Rear axle per hub (spicer) : 25 gm.

11. Cooling system (Approx) : 9.8 Ltr.

Recommended Tyre Pressure :

Veh

.C

ondi

tion

Wheels4 x 2 4 x 4

PSI Bar PSI Bar

Unl

aden

Lade

n

Front

Rear

Front

Rear

26

26

26

50

1.8

1.8

1.8

3.4

26

26

30

45

1.8

1.8

2.1

3.1

TY

RE

PR

ES

SU

RE

29

GE

NE

RA

L

FILLING CAPACITY AT A GLANCE

Engine oil upto Dipstick Max. mark - 7.7 Ltrs.

Min. mark - 5.7 Ltrs.

Engine Coolant = Antifreeze

agent + Soft Water = 9.8 Ltrs

Rear axle Oil (Tata Motors) - 1.9 Ltrs

Rear axle Oil (Spicer) - 2.2 Ltrs

Rear axle Grease / Hub (Tata Motors) - 120 gm

Rear axle Grease / Hub (Spicer) - 25 gm

Windshield Washer

reservoir = 2.5 Ltr

Power Steering System -

RANE - 1.4 Ltrs

ZF - 1.6 Ltrs

Front axle Grease / Hub (Tata Motors) - 100 gm

Front axle Grease / Hub (Spicer) - 92 gm

Fuel Tank Capacity - Single

Cab - 60 Ltrs

Dual Cab - 50 Ltrs

Transfer Case - 1.2 Ltrs

Brake Hydraulic

System 0.5 Ltrs

Clutch Hydraulic

System 0.2 Ltrs

Gearbox - 1.6 Ltrs

Front live axle oil

= 1.2 Ltr.

(4x4 version)

Veh

.C

ondi

tion

Wheels4 x 2 4 x 4

PSI Bar PSI Bar

Unl

aden

Lade

n

Front

Rear

Front

Rear

26

26

26

50

1.8

1.8

1.8

3.4

26

26

30

45

1.8

1.8

2.1

3.1

TY

RE

PR

ES

SU

RE

30

GENERAL

6. LUBRICATION & MAINTENANCE

A. LUBRICATION POINTSFor 4x2 Vehicle

Lubrication points listed below and shown on next page require greasing or oil level check and top up.

Sr. No. Description No. of points

1. Engine Oil level2. Power steering tank Oil level3. Propeller shaft-front 1 grease nipple4. Rear axle Oil level5. Rear hub Pack grease (for Tata Motors axle only)6. Gear box Oil level7. Idler arm 1 grease nipple8. Front hub Pack grease9. @ Centre link 2 nipples

@ Not applicable for facelift vehicles & 4x4 non facelift vehicles.

Note : Grease nipples must be carefully cleaned prior to greasing and the same applies to greasecups / screw plugs before they are unscrewed.

31

GENERAL

4

9

11 75

10

106 8

1 2 3

Note : Grease nipples must be carefully cleaned prior to greasing and the same applies to greasecups / screw plugs before they are unscrewed.

12

B. LUBRICATION POINTSFor 4x4 Vehicle

Lubrication points listed below and shown on next page require greasing or oil level check and top up.

Sr. No. Description No. of points

1. Engine Oil level2. Power steering tank Oil level3. Propeller shaft-front 1 grease nipple4. Rear axle Oil level5. Rear hub Pack grease (for Tata Motors axle only)6. Gear box Oil level7. Transfer case Oil level8. Idler arm 1 grease nipple9. Front hub Pack grease10. Front live axle Oil level11. Propeller shaft - Front live axle 1 grease nipple12. @ Centre link 2 nipples

@ Not applicable for facelift vehicles & 4x4 non facelift vehicles.

32

GENERAL

1. Front axle on frame 4 - 5 NA2. Torsion bar bracket 9 93. Lower wishbone bush 14 144. 2nd cross member 9 NA5. Power Steering gear box mounting to frame 8 86. Idler arm mounting to frame 8/5 8/57. Front engine mounting pad to frame 4.5 4.58. Centre link ball joint 7-9 7-99. Front anti roll bar to frame 4.5 4.510. Rear spring U bolt nut 8 811. Rear spring U bolt lock nut 4 412. Dana propeller shaft on axle 1.8 - 2.2 1.8 - 2.213. Top wishbone ball joint to stub axle 13.5 13.514. Stub axle ball joint to lower link 13.5 13.515. Bottom ball joint to lower wish bone 9 916. Brake calliper mounting to lower wish bone 7.6 - 8.8 7.6 - 8.817. Steering damper 8 - 9 NA18. Rear shock absorber mounting to frame 6-7 6-719. Front shock absorber 9 920. Hub lock 5.5 - 6.5 NA21. Dana propeller shaft to front live axle 4 NA

Sl. No. Location 4x4 4x2(in mkg)

6 C. TIGHTENING TORQUES

Sl. No. Location in mkg

22. Engine mounting front 723. Engine mounting rear 424. Center bearing mounting 825. Wheel nuts 18 - 19.526. Exhaust pipe joints catalytic convertor 2.527. Dana propeller shaft to gear box 1.8 - 2.228. Shackle mounting to frame 1429. Cab mounting 4.6 - 630. Load body bolts 6 - 731. Steering U/J cross 2.532. Steering wheel nut 533. Tie rod check nut 820. Drain Plugs

a) Engine 4 - 6b) Gear Box 5c) Transfer case 2.8 - 4.2d) Front Axle (4x4) / Rear Axle (Spicer) 2 - 3.5

21. Oil Level Plugsa) Engine Hand Tightb) Gear Box 2.5c) Transfer case 2.8 - 4.2d) Front Axle (4x4) / Rear Axle (Spicer) 2 - 3.5

33

GENERAL

6D. SERVICE SCHEDULE CHART

10

20

30

40

50

60

70

80

90

10

0

FREQ

UENC

Y

x 1000 km

x 1000 miles

SR.

No.OPERATION

DA

ILY

6 12

18

24

30

36

42

48

54

60

GENERAL

1. Wash the vehicle Periodically

2. Lubricate all grease nipples 10,000 ● ● ● ● ● ● ● ● ● ●

3. Tighten all fasteners: front grill, & fuel lines, engine, clutch hsg. radiator mtg., accelerator cable, radiator hose, 10,000 ● ● ● ● ● ● ● ● ● ●

prop. shaft centre brg. bracket/mounting bolts, U-bolts & nuts of springs, joints of pitman arm, idler arm, centre link, tie rods, upper

ball joints of top wish bone, mtg's of lower arm & lower link, steering gear box and its mtg. bracket, vacuum & hydraulic line

connections, head lamp mtg. wheel mtg. nuts, drivers cab seats mountings, axle shaft mtg., anti roll bar mtg., vacuum booster & tandem

master cylinder mtg's, clutch master & slave cylinder mtg., rear anchor plate mtg., front disk brake mtg., fuel tank mtgs.,

front suspension top rubber mtg. nut.

ENGINE

3. Check coolant level. Top up if necessary Daily ● ● ● ● ● ● ● ● ● ● ●

4. Change coolant in cooling system 50,000 or two years whichever is earlier

5. Check oil level in sump, Top up if necessary Daily ● ● ● ● ● ● ● ● ● ● ●

6. Change engine oil & oil filter cartridge 10,000 ● ● ● ● ● ● ● ● ● ●

7. Drain water from water drain plug in primary fuel filter Periodically

8. Change fuel filter element (tank side) 10,000 ● ● ● ● ● ● ● ● ● ●

9. Change both fuel filter elements 20,000 ● ● ● ● ●

10. Clean air cleaner filter element, change if red band appears on service indicator even after cleaning As and when red band appears

11. Tighten turbo charger mounting, inter cooler mounting fastners 10,000 ● ● ● ● ● ● ● ● ● ●

12. Tighten turbo charge hose connections/its mountings & inter cooler hose connection/its mountings 10,000 ● ● ● ● ● ● ● ● ● ●

13. Check inter cooler fins for dust accumulations and clean by compressed air 20,000 ● ● ● ● ●

14. Check end play of turbo charger shaft and radial clearance between turbine wheel and housing 70,000 ●

15. Check timing belt, adjust tension if necessary, replace if defective 20,000 ● ● ● ● ●

16. Replace timing belt 1,00,000 ●

17. Check all drive belts, adjust tension if necessary, replace if defective. 10,000 ● ● ● ● ● ● ● ● ● ●

18. Replace all drive belts (other than timing belt) 40,000 ● ●

19. Check injection nozzles for opening pressure & spray characteristics Check if any problem is noticed

CLUTCH AND BRAKES

20. Check level of clutch & brake fluid in containers, top up if necessary 10,000 ● ● ● ● ● ● ● ● ● ●

21. Check service & parking brakes, adjust if necessary 10,000 ● ● ● ● ● ● ● ● ● ●

22. Check front brake pads & rear brake linings, Replace if necessary 20,000 ● ● ● ● ●

23. Overhaul the following brake components and change the brake fluid in the system 30,000 ● ● ●

1) Tandem Master Cylinder, 2) Front Caliper, 3) Rear Wheel Cylinders, 4) Clutch Master

Cylinder & Slave Cylinder

FOR CONVENTIONAL BOOSTER (YELLOW)

24. Overhaul Vacuum Booster & change the felt and Polyurethane filters along with rubber bellow 30,000 ● ● ●

FOR ZERO DEAD STROKE BOOSTER (BLACK) (IF FITTED)

25. Check the performance by applying & releasing brakes when engine is running. 10,000 ● ● ● ● ● ● ● ● ● ●

The pedal should go down easily and return swiftly.

26. Lubricate linkages and check for slackness at fork. Check the gaiter for proper fitment existence of 20,000 ● ● ● ● ●

damage and replace if necessary.

27. Change filters and gaiter. 40,000 ● ●

28. Overhaul the assembly using recommended repair kit. Replace valve body& rubber reaction disc if necessary. 80,000 ●

GEAR BOX & TRANSFER CASE

29. Check oil level in gear box, Top up if necessary 10,000 ● ● ● ● ● ● ● ● ● ●

30. Change oil in gear box (also at 1st 10,000 km), if multigrade oil 80W 90 is used (non facelift) 40,000 ● ● ●

31. Change oil in gear box (also at 1st 40,000 km), if synthetic oil 75W 90 is used (facelift) - dual cone gear box 80,000 ●

32. Check oil level in transfer case (4 x 4 vehicle), top up if necessary 10,000 ● ● ● ● ● ● ● ● ● ●

33. Change oil in transfer case (4 x 4 vehicle) 40,000 ● ●

34. Clean breather on gear box 70,000 ●

34

GENERAL

6B. LUBRICATION AND MAINTENANCE SCHEDULE

10

20

30

40

50

60

70

80

90

10

0

FREQ

UENC

Y

x 1000 km

x 1000 miles

SR.

No.OPERATION

DA

ILY

6 12

18

24

30

36

42

48

54

60

FRONT & REAR AXLES

35. Check oil level in rear axle, top up if necessary (Also front live axle 4x4 vehicle) 10,000 ● ● ● ● ● ● ● ● ● ●

36. Change oil in rear axle and front live axle (4x4 vehicle) (also at 1st 20,000 km) 40,000 ● ●

37. Change grease in front & rear hubs & adjust bearing play (only for Tata Motors axle) 30,000 ● ● ●

38. Change grease in front hubs & adjust bearing play (DANA Spicer) 40,000 ● ●

39. Lubricate automatic hub lock parts (except drag sleeve assembly) by dipping in ATF oil 40,000 ● ●

SUSPENSION & STEERING

40. Check play in ball joints at front suspension, top & bottom. Replace if necessary 20,000 ● ● ● ● ●

41. Check wheel alignment, chassis height & adjust if necessary 10,000 ● ● ● ● ● ● ● ● ● ●

42. Check & adjust steering wheel free play 30,000 ● ● ●

43. Check oil level in power steering tank and top up if necessary 10,000 ● ● ● ● ● ● ● ● ● ●

44. Change oil & oil filter in power steering system 80,000 ●

45. Check condition of rubber bushes in the following, replace if necessary, 1) Top Wish Bone

2) lower wishbone 3) Anti Roll Bars 4) all suspension bump stops 30,000 ● ● ●

46. Check shock absorber & its bushes and steering damper bushes, replace if necessary 20,000 ● ● ● ● ●

ELECTRICALS

48. Check electrolyte level in battery, add distilled water if necessary 10,000 ● ● ● ● ● ● ● ● ● ●

49. Check Specific gravity of electrolyte and the charge of battery 30,000 ● ● ●

50. Check headlamp focussing & functioning of other electrical equipments & adjust 10,000 ● ● ● ● ● ● ● ● ● ●

51. Check glow plugs for continuity/short circuit, replace if required 20,000 ● ● ● ● ●

52. Check water level in windscreen washer container & top up if necessary Daily ● ● ● ● ● ● ● ● ● ● ●

CAB

53. Apply grease on door latches, door lock striker, bonnet opening lever and lock plate 10,000 ● ● ● ● ● ● ● ● ● ●

54. Apply grease on tail gate hinges & door lock inner ratchet, Lubrication with oil can 30,000 ● ● ●

WHEELS & TYRES

55. Tyre rotation & check tyre pressure 10,000 ● ● ● ● ● ● ● ● ● ●

56. Wheel balancing When tyre is removed from wheel rim

AIR CONDITIONING SYSTEM (wherever fitted)

Check torque of bolts on brackets & AC compressor 10,000 ● ● ● ● ● ● ● ● ● ●

57. Check compressor belt, adjust tension, Replace if necessary (Replace at 40,000 km) 10,000 ● ● ● ● ● ● ● ● ● ●

58. Check bubbles in receiver drier for refrigerant level 10,000 ● ● ● ● ● ● ● ● ● ●

59. Check for leak of gas / oil from pipes, joints, compressor shaft seal & cylinder head 10,000 ● ● ● ● ● ● ● ● ● ●

60. Clean condensor with high pressure water 10,000 ● ● ● ● ● ● ● ● ● ●

61. Check fan speeds for proper air flow 10,000 ● ● ● ● ● ● ● ● ● ●

62. Check clutch operation 10,000 ● ● ● ● ● ● ● ● ● ●

63. Check system pressure with gauges. Recharge if necessary 10,000 ● ● ● ● ● ● ● ● ● ●

64. Clean evaporator from its face to remove dust, foreign objects etc. 20,000 ● ● ● ● ●

HEATING / DEMISTING SYSTEM (wherever fitted)

65. Check hose joits of heating system for leakage. Tighten if necessary 10,000 ● ● ● ● ● ● ● ● ● ●

66. Check hoses of heating system for cracks. Replace if required 10,000 ● ● ● ● ● ● ● ● ● ●

67. Check blower for proper functioning. Check fuse. Replace if found blown. 10,000 ● ● ● ● ● ● ● ● ● ●

1

4 DLTC ENGINE

4 DLTC ENGINE

3

4 DLTC ENGINE

TATA 483 DL TC IC is a turbocharged engine withintercooler, and indirect fuel injection system.Aluminium cylinder head incorporates glow plugs,combustion chambers, and overhead camshaft. Arubberised timing belt drives overhead camshaft,water pump and rotary fuel injection pump fromcrankshaft. Element type heat exchanger is fittedon the right hand side of the engine and it can beeasily removed for access to water jackets. Oilpump is chain driven from crankshaft and oil filteris spin-on-throw away type. An oil separator isprovided in crank case ventilation system toseparate gases and oil droplets.

Engine has a three point mounting with twomounting points in front of engine and one underthe rear of gear box.

INTRODUCTION :

5

4 DLTC ENGINE

CONTENTS


1. Technical specification 7

2. Schematic circuits of

a) Lubrication system 8

b) Cooling system 8

c) Fuel system 9

d) EGR circuit on EURO-III Engine 9

e) Engine Breathing System 10

f) Oil Separator (Sectional View) 11

3. Special tools 12

4. Preliminary inspection of engine 13

5. Removal of engine from vehicle 15

6. Engine dismantling procedure 16

7. Tightening torques 29

8. Repair data 31

9 Inspection Engine component 37

9. Engine assembly procedure 55

10. FIP timing setting procedure (MICO) 66

14. Lucas DPC FIP (Euro II & Euro III) features & fault diagnosis 70

10. FIP timing setting procedure (LUCAS) 82

11. Turbocharger - features & trouble shooting 84

12. Catalytic Convetor 87

13. EGR System (for Euro III engines) 88

14. Engine testing 90

15. Engine trouble shooting 91

7

4 DLTC ENGINE

TECHNICAL SPECIFICATIONS

Engine model : 4DL TCIC

Type : Water cooled, indirect injection, turbo charged, and intercooled

diesel engine with Crankcase breather / oil separator &

Exhaust gas recirculation system.

No. of cylinders : 4 in line

Bore/stroke : 83 mm x 90 mm.

Capacity : 1948 CC

Max. Engine output : 64kW (90 ps) at 4300 rpm

Max. Torque : 190 Nm (19 kgm) at approx. 2000-3000 rpm

Compression ratio : 21:1

Firing order : 1-3-4-2

Air filter : Dry (paper) type

Oil filter : Spin-on full flow paper type

Fuel filter : Two stage, fine filtration

Fuel injection pump : Rotary type with electric stop solenoid

Governor : Mechanical

Engine oil capacity : Max. 7.7 liters

Weight of engine : 220 kg (dry)

Radiator frontal area : 2340 sq. cm.

Exhaust System : With Catalytic Convertor

8

4 DLTC ENGINE

SCHEMATIC CIRCUITS OF VARIOUS SYSTEMS ON 4 DLTC ENGINE

2a. Lubrication System

A. Strainer in sumpB. Oil pumpC. Oil pump relief valveD. Full flow oil filter (paper type)

Fig. 1

Fig. 2

E. Filter bypass valveF. Oil coolerH. Turbocharger

I. Crankshaft Journals etc.J. Piston cooling nozzlesK. Oil sump

2b. Cooling System

9

4 DLTC ENGINE

2d. EGR SYSTEM ON EURO-III ENGINE

Fig. 3

Fig. 4

Injector

HandPrimingPump

SecondaryFuel Filter

FIP

HP lines

Tank Cap WithBreather

Fuel returnline

FuelTank

Fuel Supplyline

PrimaryFuelFilter

2c. Fuel System (Lucas DPC for EURO II & EURO III)

VENT TO ATMOSPHERETHROUGH FILTER

10

4 DLTC ENGINE

2e. ENGINE BREATHING SYSTEM(SCHEMATIC LAYOUT)

Fig. 5

Oil Separator for Air Breather :

A step towards developing environment friendlyproducts, to eliminate the engine blow by beingemitted to atmosphere, the engine breather / oilseparator has been fitted.

The oil separator, separates oil from the blow byof the engine and sends it back to engine oilsump. The remaining air, carbon particles andother gases are sent to the inlet manifold.

There is also a spring loaded diaphragm valveprovided on the oil separator outlet to the inletmanifold. This prevents the flow of excessive ofblow-by from the oil separator to inlet manifoldin case the air filter is choked and high suctionstarts acting on outlet port of oil separator.

No leakage past diaphragm or top cover of oilseparator is permitted. Replace the assembly ifthere is any leakage.

11

4 DLTC ENGINE

2f. OIL SEPARATOR (SECTIONAL VIEW)

Fig. 6

TO AIR INTAKE

SEALING RING

OIL PORT

TO OIL CRANK CASE

DIAPHRAGMSPRING

VENTILATION HOLE 3

BLOW BY GASES

12

4 DLTC ENGINE

SPECIAL TOOLS

Sr. No. Description Part Number

1. Adaptor for checking engine compression. 2654 5890 01 01

2. Fly wheel locking pin 2654 5890 03 09

3. Spanner for crank shaft. 2654 5890 03 02

4. Drift for crank shaft front oil seal. 2654 5890 03 03

5. Drift for crank shaft rear oil seal. 2654 5890 03 04

6. Puller for crank shaft gear and sprocket. 2654 5890 03 05

7. Puller for crank shaft spigot bearing. 2654 5890 03 06

8. Spanner for FIP and Cam shaft gear. 2654 5890 05 01

9. Camshaft and FIP gear locking bolt. 2654 5890 05 02

10. Drift for valve guide. 2654 5890 05 04

11. Spacer for drift valve guide seal (Inlet) 2651 5890 06 02

12. Spacer for drift valve guide seal (Exhaust) 2651 5890 06 03

13. Support rail. 2654 5890 05 06

14. Valve spring compressor. 2654 5890 05 07

15. Drift for cam shaft oil seal. 2654 5890 05 08

16. Assembly adaptor for FIP timing checking. (MICO) 2654 5890 05 09

17. Timing rod (Lucas) 2654 5890 06 01

18. Assembly bracket for FIP timing checking (Lucas) 2654 5890 06 02

19. Assembly bracket for FIP timing checking (Lucas) 2654 5890 06 03

20. Drive square for timing belt tensioner. 2654 5890 05 10

21. Spanner for oil filter. 2654 5890 18 01

22. Engine mounting bracket attachment (To be used with engine stand) 2654 5890 24 01

23. Mandrel for clutch plate alignment. 2654 5890 25 01

24. Puller for fan pulley. 312 589 03 33

25. Socket for removal / installation of injectors. 312 589 00 09

26. Engine mounting stand. 2573 5890 24 01

27. Drift for removal of cylinder liners 2654 5890 01 03

28. Drift for installation of cylinder liners 2654 5890 01 02

13

4 DLTC ENGINE

4. PRELIMINARY INSPECTION OF ENGINE

Before proceeding to carry out reconditioning ofengine, it is desirable to have preliminaryinspection to ascer tain whether an enginereconditioning is necessary.

Common reasons for which engine is reconditionedare :

1. Loss of power

2. Excessive engine oil consumption.

3. Low engine oil pressure

4. Mechanical failures

1. LOSS OF POWER

Loss of power may be due to :a. Clogged air cleaner / loss of charge air

pressure / choked exhaust silencerb. Clutch slippagec. Brake bindingd. Defective fuel systeme. Loss of engine compression

a. CLOGGED AIR CLEANER / LOSS OFCHARGE AIR PRESSURE / CHOCKEDEXHAUST SILENCER

Loss of power with unusual black smoke fromengine exhaust indicates lack of air or low aircharging pressure to engine cylinders. Loss ofcharge pressure can be due to leakage of chargeair from outlet of turbocharger, worn out vanes ofturbocharger compressor & leakage in inletmanifold etc.

Clean air cleaner. Check all joints for air leakage. Ifpower loss with black smoke is still felt, checksilencer for choking. Clean or replace silencer ifnecessary.

b. CLUTCH SLIPPAGE

Clutch slipping can be confirmed by any of thefollowing two methods :

Drive vehicle in 1 st or 2nd gear at maximumspeed corresponding to that gear. With acceleratorpedal fully pressed, apply brake gradually with leftfoot. If engine stalls, it means that clutch does notslip.

Drive loaded vehicle in 3rd gear on level groundand let the speed drop down to approximately 15kmph. Now press accelerator pedal fully. Withslipping clutch, vehicle speed will not pick up andalso clutch burning smell will be noticed. If this

does not occur and vehicle picks up speed, itindicates that clutch does not slip.

c. BRAKE BINDING

During driving, apply brakes number of times andthen shift gear to neutral position. Check brakedrums/brake discs for overheating. If necessary,jack up axles and check wheels for free rotation.

Check Handbrake position (Released/applied)

D. FUEL SYSTEM

Check condition of fuel filter elements, fuel pumptiming, injection nozzles and fuel injection pump forproper functioning.

E. CHECKING ENGINE COMPRESSIONPRESSURE

- If loss of power is not on account of anyreasons above, check engine compression asgiven below.

- Warm up engine preferably by road drive to geta temperature of about 85 to 95o C.

Remove all injectors. Flame guard washersshould be replaced while refitting the injectors.

- Fit adaptor 2654 5890 01 01 in place of oneinjector. Tighten pressure screw using spanner312 589 00 09 to specified torque.

- Connect compression tester to adaptor andtighten vent knob.

- Crank engine. Pressure gauge needle will startrising. Continue cranking till gauge needle stopsrising any further. Note down reading. Loosenvent knob to make sure tester needle returns tozero. Repeat this operation for remainingcylinders.

- Minimum compression pressure in each cylindershould be 19 bar. Variation in compressionpressure between cylinders should not be morethan 1.5 bar.

- Low compression pressure may be due toleakage past valves / piston rings /blown headgasket. Spray small quantity of clean engine oilin cylinder showing low pressure. If compressionimproves, wear in piston rings / cylinder bore isindicated. If it does not, leakage past valves isindicated. If compression pressure of adjacentcylinder is also on lower side, it may be due toblown cylinder head gasket.

14

4 DLTC ENGINE

2. EXCESSIVE ENGINE OIL CONSUMPTION

Check oil consumption as given below :

1. Make sure that there is no external leakage ofthe oil (i.e. from the camshaft oil seal,crankshaft oil seal, oil sump gasket, cylinderhead cover gasket etc.

2. Ensure that oil separator condition is OK & noleakage in the circuit.

3. If no external leakage is found, determine oilconsumption as given below.

Caution : Do not make a rough estimate of engineoil consumption by noting the kilometers coveredby the vehicle at any random stage and finding oilconsumed from the topped up position taking intoconsideration dipstick level and oil tank capacity.

Procedure :

1. Place the vehicle on the level ground.2. Top up oil to max. level in dipstick.3. Warm up the engine.4. Take a clean vessel, place it below drain plug

of sump.5. Drain hot oil into the vessel. Drain it fully.6. Screw in oil sump drain plug and tighten it.7. Weigh the vessel along with oil. Let this

weight be 'w1' gms.8. Refill weighed oil into sump. Do not spill any

oil. The vessel used for draining should not beused for any other purposes.

9. Load the vehicle approximately to rated GVW.Drive vehicle for at least 200 km under normaloperating conditions. Let this drive distance be'D' kms.

10. Immediately after the test drive, place thevehicle at the same spot.

11. Now place the same vessel below sump.Unscrew drain plug and drain oil into thevessel. Drain oil in sump fully.

12. Weigh the vessel along with oil. Let thisweight be 'W2' gms.

13. Find out standard oil consumption as :

Note : Oil consumption of engine depends on the oilconditions (e.g. viscosity/cleanliness/quality etc.) andthe driving conditions. If the vehicle is driven in highspeeds and / or with frequent accelerations forcomparatively long time, then oil consumption mayshow variation over the specified values.

3. EXTREMELY LOW OIL PRESSURE

Check the following :

a. External leakages.

b. Oil level in sump.

c. Oil pressure indicator for proper functioning.

d. Functioning of pressure relief valve on oilpump.

e. Oil pump performance.

f. Clogged oil filter

Specified oil pressure at 4300 rpm & at 850Ctemperature

Minimum oil pressure at

Engine Max Speed Idle Speed

New 5.5 bar 1.4 bar

Old 4.0 bar 1.0 bar

If oil pressure is less than specified, it may be dueto improper functioning of oil pump or defect in oilpump relief valve.

If low oil pressure is not on account of oil pump/oilpump relief valve, wear of journals / bearings isindicated for which overhaul of engine may beconsidered.

Oil pressure can be checked with a pressure gaugeas given below :

- Remove the pipe union bolt on crank case,used to ount the oil line (crank case to vaccumpump)

- Put a suitable adaptor on crank case.

- Connect a pressure gauge on the adaptor withthe help of metallic pressure line.

- Run the engine at idling / maximum speed atspecified temeperature and measure oilpressure.

Standard oil consumption =

(W1-W2) (Wt. of oil consumed gms) x 1000

'C' (Litres/1000 km) Sp. wt. of oil (gm) x 'D' (drive dist. in km)

'C' = (W1-W2)

litres/1000 km 0.88 x D

If the oil consumption value is more than 0.8Ltr./1000 kms. then engine needs furtherinvestigation.

15

4 DLTC ENGINE

4. MECHANICAL FAILURES

Defective water pump or alternator can be asource of mechanical noise. Defect can be locatedby replacing alternator or water pump with new one.

Metallic knocking sound from engine may be dueto faulty injection, excessive clearance in main andbig end bearings, small end bush, tappets, pistonslap, seizing of piston rings, scored cylinder boreor breakage of any moving parts. Noise due todefective fuel injection equipment can be eliminatedby attending FIP/injectors. Cutting off high pressureline to individual injectors with engine running willpin point the cylinder with Diesel Knock.Overhauling of fuel system will set right this defect.

Noise also can be from turbocharger.

Dismantling of engine may be considered if stillnoise occur even after attending all abovementioned problems.

REMOVAL OF ENGINE FROM VEHICLE

Remove bonnet.

Disconnect electrical cable connections for :- Battery- Starter Motor- Alternator- Fuel injection pump solenoid switch- FICD (Fast idling control device (if fitted)- Oil pressure switch- Glow plugs- EGR System (if fitted)- Water temperature transducer- Reversing switch

Disconnect cables for :- Accelerator- Clutch- Speedometer drive

Disconnect pipe lines from :- Fuel filter to fuel injection pump- Fuel injection pump to fuel tank- Vacuum pump to vacuum booster- Power steering pump

Disconnect exhaust pipe from exhaust manifold

Drain engine lubricating oil from oil sump

Drain coolant from cooling system.

Disconnect hoses from and to radiator, Intercooler

Disconnect pipe from radiator to auxiliary tank.Disconnect A.C. pipe lines and hot water pipesconnections (AC refrigerant should be drained fromsystem as per local regulations).

Disconnect propeller shaft front end.

Remove following sub assemblies :

- Air filter, if necessary- Starter motor- Radiator with fan shroud- Clutch slave cylinder- Gear shift lever- Gear box with clutch housing and transfer

case (for procedure see gear box group)

Fix chain to front and rear engine lifting hooks andhold chain in position with crane.

Unscrew and remove engine mounting bolts.

Lift engine from vehicle with the help of crane.

Mount engine on work stand.

INSTALLATION OF ENGINE ON VEHICLE

- Check engine mounting pads for wear.Replace them if necessary.

- Install the engine in reverse sequence ofremoval.

- Tighten engine mounting bolts to specifiedtorque.

- Connect all pipes, hoses and electricalconnections.

- Fill specified quantity of oil in engine ofrecommended grade.

- Fill coolant in the cooling system throughradiator.

- Crank the engine momentarily. Let oil andcoolant circulate through the system.

- Confirm whether oil pressure indicator light isswitching off when engine is started.

- Check for any leakage, rectify if necessary.

- Top up coolant upto FULL mark in auxiliarytank, if necessary.

- Check HVAC system for correct functioning.

16

4 DLTC ENGINE

ENGINE DISMANTLING PROCEDURE -(engine mounted on work stand)

Loosen power steering pump mounting bolt.

Loosen hexagonal nut on belt tension adjuster.Refer figure 7.

Loosen lock nut.

Turn adjusting hex. nut till belt can be removed.

Remove alternator and power steering pump belt.

Loosen the hexagonal nut for belt tension adjusterfor fan belt. Refer figure 8.

Loosen lock nut and then adjust hexagonal nut tillfan belt can be removed.

Remove fan belt.

Unstake lock plates and remove fan along with hub.Refer figure 9.

Remove split pin and castle nut.

Remove fan pulley using puller 312 589 03 33.Refer figure 10.

Fig. 8

Fig. 9

Fig. 10Fig. 7

17

4 DLTC ENGINE

Remove oil pipe from block to vacuum pump.

Remove alternator mounting bolt and alternator.Refer figure 11.

Remove power steering pump pulley by looseningthree set screws.

Remove power steering pump. Refer figure 12.

Unscrew 4 set screws and remove A/C compressorassy. Refer figure 13. (if fitted)

Unlock toggle clamps. Remove clips holding fronttiming gear train covers. Refer figure 14.

Remove timing gear train covers.

Fig. 12

Fig. 13

Fig. 14Fig. 11

18

4 DLTC ENGINE

Insert timing pin 2654 5890 03 09 in crankcase.

Rotate crankshaft with spanner 2654 5890 03 02,simultaneously pressing timing pin till it locksflywheel. Refer figure 15.

Lift timing pin slightly, rotate crankshaft further andtry fitting timing pin again.

At this position it should be possible to lockcamshaft gear with timing bolt 2654 5890 05 02.Refer figure 16. This will ensure compression TDCposition of 1st piston. If not, turn crankshaftthrough one more turn.

Lock fuel injection pump gear with timing bolt, 26545890 05 02. Refer figure 17.

Loosen mounting bolt and nut of belt tensionerroller assembly. Refer figure 18.

Fig. 16

Fig. 17

Fig. 18Fig. 15

19

4 DLTC ENGINE

Depress roller by using drive square pt. no. 26545890 05 10. Refer figure 19.

Remove timing belt.

Remove

- Overflow hose from 1st injector to fuel injectionpump.

- Coolant pipe.

- High pressure injection pipe from injectors tofuel injection pump.

- Fuel pipe from fuel filter to fuel injection pump.

- Fuel return pipe from fuel injection pump to fueltank.

- FICD unit.

- Oil separator and hoses.

- Thermostat assy. and Water Valve for cabheating (if fitted).

Disconnect engine stop solenoid and cold start unitelectrical cable from fuel injection pump.

Hold fuel injection pump gear with spanner, 26545890 05 01 and unscrew mounting nut to removefuel injection pump gear. Refer figure 20.

Remove timing bolts and FIP gear.

Remove woodruff key.

Remove fuel injection pump rear mounting bolt andtaper nut, along with split sleeve.

Unscrew and remove fuel injection pump frontmounting nuts.

Remove fuel injection pump.

Remove FIP mounting bracket.

Remove starter motor assembly. Refer figure 21.

Fig. 19

Fig. 20

Fig. 21

20

4 DLTC ENGINE

Remove inlet pipes connected to turbocharger.

Remove oil inlet and oil outlet pipe connected toturbocharger. Refer figure 22.

Remove turbocharger shield.

Remove turbocharger exhaust elbow. Refer fig. 23.

Take out turbocharger assembly. Refer figure 24.Turbocharger should be stored with all openingscovered suitably to prevent entry of foreign matter.

Take out exhaust manifold by loosening nuts. Referfigure 25.

Fig. 23

Fig. 24

Fig. 25Fig. 22

21

4 DLTC ENGINE

Remove inlet manifold by loosening allen screwusing allen key. Refer figure 26.

Using spanner, 2654 5890 05 01 lock camshaftgear. Refer figure 27.

Unscrew and remove camshaft gear mountingscrew with spacer.

Remove camshaft gear and woodruff key.

Remove belt tensioner locking screw and timinggear train rear cover mounting screw at cylinderhead. Refer figure 28.

Remove cylinder head cover. Refer figure 29.

Fig. 27

Fig. 28

Fig. 29Fig. 26

22

4 DLTC ENGINE

Unscrew and remove cylinder head mounting boltsin reverse order of tightening. Refer figure 30.

Slightly lift cylinder head to clear locating hollowdowel in crankcase and remove it.

Uniformly and evenly unscrew clutch pressure platemounting screws and remove clutch pressure plateand clutch disc.

Lock flywheel suitably and unscrew crankshaftpulley mounting bolt. Refer figure 31.

Remove crankshaft pulley.

Remove crankshaft gear using puller 2654 589003 05. Refer figure 32.

Remove

- Tensioner roller.

- Fan mounting bearing block. Refer figure 33.

- Idler roller.

- Timing gear train rear cover.

Fig. 31

Fig. 32

Fig. 33Fig. 30

23

4 DLTC ENGINE

Remove

- Oil filter and filter mounting adaptor. Refer figure34.

- Oil cooler heat shield.

- Oil cooler.

Note : Do not loosen 4 screws in the centre.

- Water pump. Refer figure 35.

- A/C compressor mounting bracket. Refer figure36.

- Water elbow.

- Power steering pump mounting bracket. Referfigure 37.

Fig. 35

Fig. 36

Fig. 37Fig. 34

24

4 DLTC ENGINE

Uniformly and evenly unscrew oil sump mountingscrews and remove oil sump. Refer figure 38.

Unscrew and remove oil pump mounting bolts.

Tilt oil pump towards front end and remove chainfrom oil pump drive sprocket gear.

Remove oil pump. Refer figure 39, 40.

Remove ladder frame by removing setscrews.Refer figure 41.

Remove crank case front cover with crankshaftfront oil seal. Remove oil seal. Refer figure 42.

Remove oil pump drive chain.

Fig. 41

Fig. 42

Fig. 38

Fig. 39 For 4 x 2 Vehicle

Oil Pump assemblyFig. 40

25

4 DLTC ENGINE

Carefully remove combustion deposits on top endof cylinder bores, preferably by a broken piston ringor by ridge cutter.

Turn crankshaft and bring a pair of piston to BDC.

Unscrew the connecting rod bearing cap mountingnuts. Refer figure 43.

Remove connecting rod bearing caps with bearingshells.

Push these piston assemblies out of cylindersusing wooden handle of mallet.

Remove connecting rod bearing shells and dulymark them with paint on their backs.

Assemble connecting rod bearing caps to theirrespective connecting rods.

Verify serial numbers on connecting rod bearingcaps and connecting rods.

Remove remaining pair of piston in same manner.

Remove piston pin spring clips with suitable plier.Refer figure 44.

Remove piston pin from piston by pushing themout using soft drift. Refer figure 45.

Remove connecting rod.

Fig. 43

Fig. 44

Fig. 45

26

4 DLTC ENGINE

KEEP PISTON AND PISTON PIN IN SETS.

Unstake lock plates for flywheel mounting screws.

Unscrew flywheel mounting screws.

Remove flywheel. Refer figure 46.

Unscrew and remove main bearing cap mountingbolts. Refer figure 47.

Remove main bearing caps with bearing shells.

Remove crank shaft with rear oil seal. Refer figure48.

Remove crank shaft main bearing shells and thrustwashers from crank case. Duly mark main bearingshells with paint on their backs.

Assemble main bearing caps to their respectivepositions in crank case.

Remove oil pump drive sprocket gear from crankshaft using puller, 2654 5890 03 05. Refer figure 49.

Fig. 47

Fig. 48

Fig. 49Fig. 46

27

4 DLTC ENGINE

Remove drive shaft spigot bearing from crankshaft using puller, 2654 5890 03 06. Refer figure 50.

Unscrew banjo bolt and remove assembly pistoncooling nozzles from cylinder crank case.

CYLINDER HEAD DISMANTLING

Remove

- Glow plugs. Refer figure 51.

- Injector over flow hoses.

- Injectors with flame guard, flame guardwasher and sealing washer. Refer figure 52.

Fig. 50

Fig. 51

Fig. 52

28

4 DLTC ENGINE

Unscrew cam shaft bearing cap mounting nuts (first5th and 1st caps, next 4th and 2nd caps, lastly 3rdcap.) Refer figure 53.

Remove cam shaft bearing caps.

Remove cam shaft with oil seal.

Remove tappets and shims and place themcarefully in correct sequence. Refer figure 54.

Fit support rail, 2654 5890 05 06 to cylinder head.Refer figure 55.

With spring compressor, 2654 5890 05 07compress valve springs and remove valve lockhalves. Refer figure 56.

Remove valve lock retainers, valve springs, valvespring seats and valves. Place them in correctsequence.

Fig. 54

Fig. 55

Fig. 56Fig. 53

29

4 DLTC ENGINE

TIGHTENING TORQUES

Description Torquekgm.

Main bearing cap bolts M12x1.5 11

Connecting rod cap nut M9x1 5

Cylinder head screws M12x1.5 (as per the procedure prescribed).

First stage 5.

Second stage 7.

Third stage 10.5

Screw plug for oil hole in cylinder head M 12x1.5 3

Injector to cylinder head 9

Cylinder head cover nuts M6 0.8+0.2

Screw plug for oil hole near oil pump M 14x1.5 5

Oil sump screw M6. 0.8

Front lower cover to front cover M6 1

Sealing plug for oil gallery, front and rear M14x1.5 3.5

Screw plug for water hole in cylinder head M 8x1 2

Oil sump drain plug M16x1.5 5 ± 1

Assy. front cover to cylinder crankcase screw M6 1

Front lower cover to cylinder crankcase M6 1

Plug for TDC checking hole 3

Flywheel mounting screw M10x1 5

Crankshaft pulley to crankshaft bolt M14x1.5 4 + 600

Belt tensioner adjuster bolt M8 2

Timing belt idler and bearing housing to crankcase M8 2.3

Nut for drive belt tensioner 2

Camshaft gear to camshaft screw M10 4.5

Camshaft bearing cap mounting nuts M8 1.5

Assy. support to cylinder crankcase screw M8 2.3

FIP to support bracket nut M8 2.3

Flange to gear for locking screw M8 1.2

FIP gear to FIP shaft nut 5

Cap nuts on high pressure line 2

Air filter to air inlet elbow M8 2.5

Stay to air filter screw M6 0.6

Stay cylinder head screw M8 1

30

4 DLTC ENGINE

Description Torquekgm.

M12 Screw/bolts used on fuel filter mounting bracket 8

Exhaust manifold on cylinder head nut M8 2+0.3

Inlet manifold on cylinder head cap screw M8 2

Air inlet elbow to inlet manifold screw M8 2

Starter motor on flywheel housing M10 3

Alternator bracket to cylinder crankcase bolt M8 2.3

Alternator to bracket bolt M10 2

Clamp to support fip screw M8 2.5

Clamp to alternator screw M10 3

Glow plug to cylinder head 2.2

Glow plug connections 0.4

Oil pump on cylinder crankcase 1.5

Assy. strainer to assy. housing screw M6 1

Oil pressure switch on cylinder crankcase 3

Oil cooler boit M8 3.2

Assy. heat exchanger to oil cooler cover M8 2-0.5

Sealing plug for water drain hole AM14 x 1.5 4

Piston cooling nozzie mounting screw 1

Fan mounting bolts M8 3.5

Water pump to cylinder crankcase screw M6 1

Thermostat housing to cylinder head nut M8 0.8

Thermostat cover to thermostat housing nut M6 0.8

Water inlet elbow to cylinder crankcase screw M8 1.5

For clamping assy. pipe line screw M8 2

Temperature transducer on thermostat housing 1.5

Engine support arms on cylinder crankcase M10 4

Lifting hook to cylinder head screw M8 2.5

A.C. compressor (SVL) to a/c compressor bracket (M8, 4 nos.) 2.4 to 3.6

A.C. compressor bracket to crankcase (M10, 4 nos.) 6+0.5

A.C. compressor (subros) to A.C. compressor bracket. (M8, 4 nos.) 3.2+0.3

Engine support front to front mounting pad bolt M12x1.5 7

Gear case cover to rear mounting pad nut M10 4

Clutch housing to cyl. block M10 4.6

Fan shroud to radiator screw M6 1

Radiator rnounting screw M8 2

31

4 DLTC ENGINE

REPAIR DATA

CYLINDER BLOCK

Pressure test cylinder block 70O to 80O Cfor leakages of water at a and 5 bartemperature of and at apressure of

Height of crank case 303.9/304.1 mm(Dimension A)

Crankshaft axis from 236.3/236.38 mmcrankcase top surface(above dimension withMB caps and front coverinstalled)

Maximum permissible Length wise ‘B’ 0.030 mmunevenness of Cross wise‘C'0.015 mmcrankcase mating surfacewith cylinder head

Maximum permissible out 0.2 mmof parallelism betweencrankcase top and bottommachined surface

Maximum permissible 0.04 mmshift in perpendicularityof cylinder bore fromcrank shaft axis whenchecked at 200 mm fromcrank shaft center line

Maximum permissible 0.01 mmtaper and ovality of cylinder bore

- Liner inner dia 83 ± 0.005

- Cylinder block parent bore 86.00 to 86.02 mm to be finished to size

- Honing of cylinder bores - Please refer separatesection on liner

PISTON & PISTON BORE SIZES

Stage Cylinder Bore Pistondia mm stamped

Standard 83.00 A83.01 B83. 02 C

Standard I 83.03 A183.04 B183.05 C1

Piston to bore clearance 0.07 to 0.09 mm

PISTON RINGS

Type Ring Lateral Buttof ring thickness clearance clearance

in piston in cylindergroove bore

mm mm mm

1stCompression 2.5 0.05/0.082 0.25/0.50

2ndCompression 1.970/1.990 0.04/0.08 0.3/0.5

3rdOil control 2.975/2.990 0.03/0.065 0.1/0.3

Maximum permissible difference 1.5 gmin weights of piston with pin andrings in one engine

Fig. 57

32

4 DLTC ENGINE

MLS gasket (Multi layer steel) cylinder head gasketsare available in 1.5 mm / 1.6 mm thickness only.

In this case gasket thick can be identified by part no.punched on the gasket.

For 1.5 mm thick : 60-33155-40

For 1.6 mm thick : 60-33155-50

CYLINDER HEAD

Permissible unevenness Length wise 0.03 mmof cylinder head mating Cross wise 0.015 mmsurface

VALVE GUIDES

Stage Valve guide Valve guidebore in out side

cylinder head diametermm mm

Standard 13.98/13.998 14.028/14.046Standard 1 14.008/14.08 14.278/14.296

Valve guide inside diameter 7.98/7.995 mm

Valve guide installationheight (from washer seat 15.8/16.3 mmlocation for spring)

PISTON GASKET IDENTI-PROJECTION THICKNESS FICATION

0.45 to 0.55 mm 1.5 mm 1Notch0.56 to 0.65 mm 1.6 mm 2 Notches0.66 to 0.75 mm 1.7 mm 3 Notches

Max. difference between piston projections of any twopistons in crank case should not exceed 0.12 mm.

Fig. 58 Valve Dimension

Fig. 59 Valve seat Dimension

VALVE SEAT

VALVE / VALVE SEAT DIMENSIONS (in mm)

INLET EXHAUSTMaximum run 0.2 0.2out of valve facewith respect tovalve stem

Maximum run 0.03 0.03out of valveseat with respectto valve stem

Distance of 0.7/0.95 0.7/0.95valve head fromcylinder head matingsurface withcrank case

Valve stem 0.05 / 0.06 /

clearance 0.087 0.097

Permissible ovality 0.01 0.01of valve seat

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VALVE SEAT DIMENSIONSINLET EXHAUST

Valve seat angle (ø) 450 -15' 450 -15'Valve seat dia in mm 36.9 31.0cylinder head ‘F’Distance between mm 1.85 1.95cylinder head matingsurface with crankcase to valve seat incylinder head ‘G’Maximum run out of mm 0.04 0.04valve seat in cylinderhead with respect tovalve guide axis

VALVE SEAT INSERTS

Valve seat insert & bore dia in cylinder head

Stage Valve seat Valve seatinsert bore in insert outcylinder head side diameter

mm mm

INLET

Standard 39.9/39.925 40.08/40.105

Standard 1 40.2/40.225 40.38/40.405

EXHAUST

Standard 33.95/33.975 34.08/34.105Standard1 34.25/34.275 34.38/34.405

Depth of bore Thickness ofin cylinder valve seat

head for valve insertseat insert

mm mm

INLET & 9.0/9.2 7.2/7.4EXHAUST

VALVE TIMING

Inlet opens - 270 B.T.D.C.

Inlet closes - 490 A.B.D.C.

Exhaust opens - 720 B.B.D.C.

Exhaust closes - 230 A.T.D.C.

Fuel injection - Refer the FIPtiming settingprocedure

TAPPET & TAPPET BORE DIMENSIONS

Out side Diameter Tappet bore inof tappet cylinder head

mm mm

Standard 35.45/35.466 35.5/35.525Standard I 35.65/35.666 35.7/35.725

Diametral clearance oftappets in cyl. head bores0.034 to 0.075 mm

CRANKSHAFT

Stage Crank case main Crank shaftbearing bore main bearingdiameter with journalbearing shell diameter

mm mm

Standard 60.04/60.06 59.98/60.0Standard1 59.94/59.96 59.88/59. 9Repair 1 59.79/59.81 59.73/59.75Repair 2 59.54/59.56 59.48/59.5

Stage Connecting rod big Crank pinend bore diameter journalwith bearing shell diameter

mm mmStandard 50.02/50.04 49.98/49.995Standard1 49.92/49.94 49.88/49.895Repair 1 49.77/49.78 49.73/49.745Repair 2 49.52/49.54 49.48/49.495

Stage Width of 4th mainbearing journal mm

Standard 27.0/27.052

Standard1 27.1/27.152

Repair 1 27.2/27.252

Width of 1st, 2nd, 3rd and 5th 27.0/27.2 mmmain bearing journalsWidth of crank pins 24.5/24.7 mmThickness of 4th main 2.72/2.67/2.62bearing thrust washers 2.57/2.52 mmEnd play of crank shaft 0.07/0.252 mmFillet radius of crank pins 1.75/2.25 mmFillet radius of main journals 2.25/2.75 mmMaximum permissible taper 0.005 mmand ovality of main bearing journalsMaximum permissible taper 0.005 mmand ovality of crank pins

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Maximum permissible run out 0.1 mmof 2nd, 3rd and 4th mainbearing journals whensupported at 1st and 5thmain bearing journals

Maximum permissible out 0.01 mmof parallelism betweencrank pin and main bearingjournal axis

Pretension of main 0.067/0.134 mmbearing shells

Hardness of crank shaftmain bearing and crankpin journals 53 to 59 HRC

Main bearing parent bore dia 63.72/63.739 mm

Maximum permissible 0.01 mmtaper of main bearingparent bore

Maximum permissible ovality 0.03 mmof main bearing parent bore

Main bearing clearance 0.04 to 0.08 mm

CAMSHAFT

Camshaft bearing Camshaft bearingjournal bore journal diameterdiameter in mm

cylinder head mm

Standard 28.0/28.021 27. 937/27.95Standard1 27.9/27.921 27.837/27.85

Bore dia in 1st 50.0/50.025& 5th cap for front & rearoil seals

Maximum permissible 0.025 mmrun out of cam shaftbearing journal

Maximum permissible 0.08 - 0.15 mmaxial play of camshaft in installedcondition

Camshaft bearing 0.03 to 0.064 mmclearance

Hardness of cam lobes 57 - 62 HRC

CONNECTING ROD (Dimensions)

Connecting rod small end

Stage parent bore bush insidediameter diameter

mm mm

Standard 31.0/31.02528.02/28.033Standard1 31.2/31.225

Maximum permissible taper 0.01 mmand ovality of connectingrod small end parent bore

Connecting rod small end 28.02/28.033 mmbush inside diameter (to befinished after installation)(Piston pin oiled has thumbpush fit in small end bush)

Maximum permissible 0.05 mmout of parallelism (bend)between connecting rodsmall end and big endparent bores

Center to center distance 145.0/145.040 mmbetween connecting rodsmall end and big endparent bores

Maximum permissible 0.05 mmtwist of connecting rodmeasured at a distanceof 50 mm from centreline of con-rod

Connecting rod big 53.69/53.709 mmend parent bore diameter

Maximum permissible taper 0.01 mmand ovality of connecting rodbig end parent bore

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Maximum permissible 0.005 mmtaper and ovality ofcon. rod small endbush inside dia

Pre-tension of connecting rod 0.060/0.120 mmbig end bearing shells

Maximum permissible 5.0 gmdifference in weight ofconnecting rods in one engine

Connecting rod big end axial play 0.1/0.4 mm

Connecting rod big end clearance 0.04 to 0.076mm

Small end clearance 0.007 to 0.025 mm

PRECOMBUSTION CHAMBER

Pre-combustion chamber 32.043/32.073 mmcollar out side diameter

Pre-combustion chamber 32.0/31.975 mmcollar bore in cylinder head

Height of pre-combustion 4.02/4.03 mmchamber collar

Height of pre-combustion 4.0/4.02 mmchamber collar bore incylinder head

Projection of pre-combustion 0 / 0.03 mmchamber above cylinder headmating surface with crank case

INJECTION NOZZLE

Nozzle opening pressure (bar)

LUCAS MICO

New 143 to 152 135 to 140Old At least 140 At least 132

Maximum permissible variationin injection nozzle pressureLUCAS - 140 - 150 bar & MICO - 132 - 143 bar

OIL PUMP (dimensions)

Maximum distance from drive 86.3 mmgear face to sprocket face.

Distance between drive gear 0.1/0.2 mmand drive shaft end

Axial play of assembly drive shaft 0.04/0.08 mm

Backlash between oil 0.15/0.25 mmpump gears

Bore diameter in oil pump 12.0/12.01 mmhousing for drive gear shaft

Bore diameter of sprocket gear 11.95/11.96 mm

Bore diameter of drive gear 11.945/11.96 mm

Shaft diameter of drive gear 11.975/11.985 mm

Shaft diameter of driven gear 11.925/11.935 mm

Bore diameter for driver gear 11.9/11.91 mmshaft in housing

Oil Pump Pressure Relief Valve

- Opening Pressure 7 + 0.5 bar

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PISTON COOLING NOZZLE- Nozzle opening pressure 1.4/1.9 bar

- Jet height at pressure of 144 mm2.3/1.7 bar

- Flow rate with SAE-30 oil 0.8/1.1 Ipmat 400C and @ 3 bar

OIL PRESSURE SWITCHNC contact opening pressure 0.6/0.9 bar

THERMOSTAT- Start opening temperature 830 + 20 C at 0.1 mm

(For exports vehicle)

- Full open temperature 950 + 20 C at 8.0 mm

valve travel

- By pass port closed at or 930Cbefore

Fig. 60 oil pump assembly (For 4x2 vehicles)

- Leakage through main 180 to 250 Ipm (Max)valve (including seepage

hole) at room temperature

and pressure of 1 kg/cm2

- Maximum leakage

through bypass at full 1.5 Ipm

open temperature or main

flow rate of 130 Ipm

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CYLINDER BLOCK

Check water jackets and oil passeges for leaks/cracksat air pressure of 5 bar under water.

Check block for cracks by pressure testing method.Refer Figure 61

Check crank case mating surface with cylinder headfor unevenness with help of straight edge and feelergauge. Refer Figures 62 & 63

If necessary grind this surfaces just to clearunevenness.

Ensure that the minimum height of crank case is notless than 303.9 mm. Cylinderblock needs to bereplaced if height is less than this limit. Thoroughlyclean main bearing caps and corresponding machinedsurfaces of crank case.

Install main bearing caps without bearing shells in theirrespective positions on crank case.

Ensure that serial numbers on crank case and mainbearing caps are matching. Also caps are in serialorder and notches for bearing shells are on same side.

Tighten main bearing cap mounting bolts to specifiedtorque. Refer Figure 64

Fig. 62

Fig. 63

Fig. 64 Fig. 61

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Check crank case main bearing parent boredimensions - Refer Figure 65

Since a slight clearance exists between mainbearing cap dowel pins and corresponding dowelholes in crank case, it is possible that mainbearing cap once removed may be installed offcenter, by which dimension of main bearing parentbore will be different in different directions. If thereis a difference noticed in main bearing parent boredimensions, main bearing cap can be centralizedby lightly tapping it with mallet in required directionafter loosening main bearing cap mounting bolts.

If main bearing parent bore is slightly more thanmaximum permissible limits, it is possible toreclaim crank case. Main bearing cap matingsurface may be slightly faced after removingdowels. Parent bore should then be finished on asuitable line boring machine after fitting newdowels.

Install new pairs of main bearing shells accordingto main bearing journal diameter. Make sure thatsecuring lugs of bearing shells are properly seatedin grooves of crank case and main bearing caps.

Install main bearing caps with bearing shells in theirrespective positions on crank case.

Tighten main bearing cap mounting bolts tospecified torque - Refer Figure 66

Measure main bearing bore dia. - Refer Figure 67

Fig. 65

Fig. 66

Fig. 67

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Measure pre tension of main bearing shells with afeeler gauge after loosening corresponding mainbearing cap bolts opposite side of bearing shell lug.

Main bearing shells are precision finished andshould not be bored or scraped.

Select new pair of thrust washer according to crankshaft 4th main journal width.

CYLINDER BORES

Clean cylinder bores thoroughly.

Check cylinder liner dia., taper and ovality.

Refer Figures 68 & 69.

If taper and ovality is found to exceed specifiedlimits or liner is excessively worn out/scoredcylinder liners are to be replaced.

Fig. 68

Fig. 69

REMOVAL, INSTALLATION AND MACHINING OFCYLINDER LINERS

Cylinder block should be pressure tested for cracksand leakages as per procedure. Cylinder block withcracks should be discarded.

REMOVAL1. Keep cylinder block upside down on hydraulic

press such that bore from which liner is to beremoved lies clear in machine table slot.

2. Ensure that the block is resting squarely onmachine bed.

3. Press out liners individually using drift, 26545890 01 03 and a suitable distance piecebetween press ram and drift. Make sure thatdistance piece is also seating squarelybetween drift and ram.

INSTALLATION OF LINERS IN CYLINDERBLOCKThoroughly clean bores of cylinder block.

Thoroughly clean liners.

Place cylinder block on hydraulic press ensuringthat oil sump mating face is resting evenly andsquarely on bed.

Do not smear oil on liners.

Place liner with proper orientation (matchingminimum / maximum ovality axis) in cylinder bore

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and make it at right angles to cylinder block topsurface in longitudinal and crosswise directionsusing precision tri-square.

Press liner using drift 2654 5890 01 02. Use awooden spacer about 100 mm thick between pressram and drift. Pressing force should be within 4 to6 tonnes.

Similarly, press all other liners.Liners damaged during installation should beremoved and replaced with new ones.

FINISHING OF CYLINDER BLOCK WITH LINER

Machine all bores to 82.915 to 82.945 mmdiameter.

NOTE

It is very important that the axis of the bores areparallel to each other and are right angle to theaxis of crankshaft. Permissible shift inperpendicularity of bore from crankshaft axis whenchecked at 200 mm from crankshaft centre line is0.040 mm.

Therefore, we recommended use of pillar typeboring and honing machines.

If portable boring bar is used, check and cleanmating surface of boring bar and cylinder block andcentralise boring bar as accurately as possible inbore.Finish bores by honing to 83.00 ±0.005 mmdiameter. Honing should be done in three stages asfollows.

STAGE - I - ROUGH HONING

Use honing stone of grit 60. Honing speed shouldbe approximately 100-120 rpm and approx. 50double strokes per minute. Under these conditionsleave about 0.02 mm material for second stagehoning.

STAGE - II - BASE HONING

STICK SPECIFICATION - 39C8018 VKP TR 22 withpressure 3-4 kg/sq.cm. Honing speed should beapproximately 50-60 rpm & 25 double strokes perminute. This operation should be completed in 15double strokes.

Fig. 70 - Cylinder block with liner

STATE - III - PLATEAU HONINGSTICK SPECIFICATION - 39C400 JVM1 TR 22 (GNO)

Honing speed should be approx. 50-60 rpm and 25double strokes per minute. This operation should becompleted in 5 to 8 double strokes with low pressureof 2.0 to 3.0 kg/sq.cm.

NOTE :- Adjust honing stick travel to ensure that stickprojects by approx. 20 to 25 mm from top and bottomof bore during honing. Use plenty of kerosene duringhoning operation.

Clean cylinder block thoroughly and if engine assemblyis not be taken up immediately, apply grease onmachined surface of cylinder block.

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PISTONS AND PISTON RINGSPlease refer figures 71 & 74 for profiles of pistonrings & piston. Remove piston rings from pistonusing ring expander.

Remove carbon deposits from piston. Clean pistonand piston rings thoroughly.

Piston rings used :

Top - Moly coated

Middle - Taper faced

Bottom - Chrome plated conformable oil control ring

Identify all rings bore wise & tie them together. Incase rings have to be re-used, they have to beinstalled in same pistons from which they weretaken out.

Examine pistons for cracks, scoring, otherdamages, ring groove wear, piston pin bore wear,spring clip groove wear/damage etc.

Even if one piston has any of these defect, pistonset has to be replaced as a whole.

Examine piston rings for scoring, lateral clearancein piston ring groove and butt clearance in cylinderbore. Refer Figures 72 & 73

Butt clearance of piston ring should be measuredin unworn portion of cylinder bore.

Even in one piston ring has any of these defects,ring set has to be replaced as a whole.

Pistons have to matched as per size (Standard &Standard I) stamped on its head with respect tocylinder bore size.

Install piston rings in their respective positionsusing ring expander. Stagger piston rings gaps suchthat they are 1200 apart.

Fig. 72

Fig. 73

Fig. 74 - Piston profile Fig. 71 - Piston ring profile

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CYLINDER HEADUsing a straight edge and feeler gauge, checkcylinder head mating surface with crank case.Refer Figures. 75 & 76

If unevenness exceeds permissible limits, replacecylinder head.

Machining of cylinder head parting surface is notrecommended.

If height of cylinder head is less than 139.9 mm ithas to be discarded.

VALVES

Clean valves. Remove oil, carbon etc.

Valves with burnt heads, excessive scoring andwear on stem should be replaced.

Check valve head thickness. If it is less thanspecified limits replace valve. Valves have to bereplaced as a set only.

Check valve seat run out with respect to valvestem.

Refer Figure 77 If it exceed specified limit replacevalve. No attempt should be made to straightenbent valves. If valve is free from any other defectsexcept worn out seat, then only it can be re-machined on valve grinding machine as follows:

- Clamp valve on grinding machine jaws as closeas possible to valve head.

- Adjust grinding angle on graduated scale toachieve correct valve seat angle.

- Feed valve slowly towards grinding wheel untilwheel just touches valve head.

- Grind at low feed until valve seat is just clean allaround.

Note :

After grinding valve head thickness should not beless than specified values. Please refer page 32 fordetails.

Fig. 75

Fig. 76

Fig. 77

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VALVE GUIDES

In case of valve stem sticking in valve guide bore orexcessive clearance between them, remove valveguide from cylinder head using drift 2654 5890 05 04.- Refer Figure 78

Remove valve guide seal. Check condition.

Check valve guide bore diameter in cylinder head. Ifnecessary, ream valve guide bore to next over size.

Install matching size valve guide in cylinder head usingdrift, 2654 5890 05 04 and spacer, 2654 5890 05 05.Refer Figure 79.

It is desirable to ream (machine) ID of valve guides ininstalled condition (on cylinder head) to attainconcentricity with tappet bore & to maintain theirperpendicularity with cylinder head bottom face. ReferFigure 80.

Fit valve guide oil seals.

Fig. 78

Fig. 79

Fig. 80

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VALVE SEATS OF VALVES

Check valve seat height with respect to cylinderhead mating surface. Replace valve seat inserts ifthey are worn out beyond specified limit.

Cut exhaust and inlet valve seats with a 450 cutter.Refer Figures 81 & 82

Valve seat must be absolutely faultless andwithout any chatter marks.

If necessary lap valve seats and finish by usingsuitable hand grinder or by using lapping paste onvalve itself.

Smear valve seat with carbon blue. Install valve inguide and turn it slowly under axial pressure.

Contact line on valve seat must be around entirecircumference at equal width.

Distance between narrow diameter of valve face tocontact line should be minimum 0.5 mm. - ReferFigure 83

Check for leakages through valve seat by pouringkerosene on valve head. Kerosene must not seeppast valve seat.

Fig. 81

Fig. 82

Fig. 83

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VALVE SEAT INSERTS

For removing valve seat inserts from cylinder headuse suitable boring machine. Bore old insert thin(about 0.5 mm thickness) and then pry it out.

Alternatively use a suitable turning tool to cut anannular groove into valve seat insert and then pullit out with a suitable puller. In order to avoiddamage to cylinder head, place soft protectivesheet metal under supports of puller.

Measure valve seat insert bore in cylinder head.

If boring and prying is done carefully withoutdamaging valve seat insert bore, fitment of an oversize valve seat insert will not be necessary.

Re-machined valve seat insert bore in cylinderhead must be exactly at right angle to cylinderhead mating surface with crank case. All specifieddimensions should be strictly maintained to ensureproper interference of valve seat insert in its bore.

Clean valve seat insert and its bore in cylinderhead thoroughly.

Just before installation.

- Place valve seat inser t in a mixture ofMethenol and dry ice for about 20-30 minutesto bring its temperature down.

– Heat cylinder head to approximately 80OC inwater bath.

Install valve seat insert in cylinder head borequickly by slight hammering. - Refer figures 84& 85

Machine valve seat in cylinder head.

CRANK SHAFT

Clean and carry out visual inspection of crank shaftfor following.

Over heating of journals.

Scoring marks on journals.

Cracks, which should be checked on magneticcrack detector.

Check hardness of journals.

Check crank shaft run out by supporting it on V-block at 1st and 5th main bearing journals - ReferFigure 86

Fig. 84

Fig. 85

Fig. 86

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If run out exceeds permissible limits, straighten crankshaft in cold condition on press carefully.

Similarly check lateral and radial run out of flywheelmounting flange.

Check crank shaft main bearing and crank pin journaldimensions.

If necessary, grind crank shaft main journals and crankpin journals to next repair size.

Maintain correct fillet radii for all journals and pins.

Care must be taken during grinding to ensure that widthof journals is not increased.

Should it be necessary to grind sides of 4th mainbearing journals, grind it to next over size.

Re-chamfer oil holes on journals to avoid scoring ofnew bearing shells.

Finish journals by lapping them with 320 grit lappingcloth of suitable width.

After grinding recheck main bearing and crank pinjournal dimensions.

Also recheck run out of crank shaft.

We do not recommend balancing of crank shaft infield.

Thoroughly clean crank shaft with kerosene. Use wirebrush for cleaning oil holes.

Apply grease to all machined surface, if crank shaftis to be stored. Crank shaft must always be stored invertical position.

CAM SHAFT

Carry out visual inspection of cam shaft for:

- Over heating of journals.

- Scoring marks on journals and cam lobes

- Cracks, which should be checked on a magneticcrack detector.

Check hardness of cam shaft journals and cam lobes.

It should be 48-54 HRC.

Check cam shaft run out at 2nd, 3rd & 4th journal bysupporting it on V-block at 1st and 5th journal. ReferFigure 87

CONNECTING RODS

Inspect connecting rod small end bush and ifnecessary remove it. Refer Figure 88

Check connecting rod small end parent boredimension.

We do not recommend machining of con rod smallend parent bore in field.

Ensure that connecting rod big end and small endaxes are parallel to each other as specified.

Fig. 87

Fig. 88

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Oil parent bore in connecting rod.

Install new bush in such a way that slit ispositioned at approximately 450 from vertical axis.

Drill oil hole in new bush.

Finish connecting rod small end bush bore on aconnecting rod boring machine. Alternatelyconnecting rod small end bush may be reamed.

Install connecting rod bearing caps without bearingshells on connecting rod.

Tighten connecting rod bearing cap mounting nutsto specified torque. Refer Figure 89

Ensure that identification numbers for connectingrod and connecting rod bearing cap are matchedand notches for bearing shells are on same side.

Check twist and bend of connecting rod by usingnew piston pin in connecting rod small end bush.Dimension between con rod big end & small endaxes to be as specified. Refer Figures 90 & 91

Measure twist and bend of connecting rod withfeeler gauge with respect to vertical face ofconnecting rod alignment gauge in vertical andhorizontal plane at a distance of 50 mm from linejoining centers of connecting rod small end and bigend bosses.

If necessary, straighten connecting rod in coldcondition. Since a slight clearance exists betweenconnecting rod bolts and corresponding connectingrod bearing cap holes, it is possible that connectingrod bearing cap once removed may be installed offcenter. If there is a difference noticed in connectingrod big end parent bore dimension in differentdirections, bearing cap can be centralized by lightlytapping it with mallet in required direction afterloosening cap mounting nuts.

Fig. 89

Fig. 90

Fig. 91

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Check big end parent bore dimension. ReferFigure 92

If big end parent bore is slightly more thanmaximum permissible limits, it is possible toreclaim connecting rod. Connecting rod bearing capmating surface may be slightly faced.

Parent bore should then be finished on aconnecting rod boring machine.

If one or more connecting rods are to be replaced,ensure that difference in weight are withinpermissible limits.

Install new pair of connecting rod bearing shellaccording to size of crank pin journal diameter,making sure that securing lugs of bearing shellsare properly seated in grooves of connecting rodand cap . Refer Figure 93

Install bearing cap with shell on connecting rod.

Tighten cap mounting nuts to specified torque.Refer Figure 94.

Fig. 92

Fig. 93

Fig. 94

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Measure bearing dia. Refer Figure 95.

Measure pretension of bearing shell with feelergauge after loosening bearing cap mounting nut onopposite side of bearing shell lug. Refer Figure 96

Bearing shell are precision finished and should notbe bored or scraped.

INSPECTION OF INJECTION NOZZLE :

Checking nozzle opening pressure

- Connect injector assembly to nozzle tester.

- Slowly depress nozzle tester lever and readpressure gauge when nozzle starts opening.

- If opening pressure is not as per specifiedvalue, then adjust as required by selectingproper shims.

Check nozzle for leakage

- Slowly depress nozzle tester lever untilpressure gauge shows 125 bar. The nozzle isleak proof, if no drop comes out of nozzle tipwithin 10 seconds.

- Rectify the leak by cleaning the nozzleelements.

Replace nozzle if necessary.

Checking nozzle spray

- Close shut-off valve.

- Depress nozzle tester lever 4 -5 times. Thenozzle will then buzz very softly. Theautomization is satisfactory when an jet conehave uniform closed contour and is finelyautomized.

Inspection of glow plugs

- Check glow plugs for short circuits and or forburning. Replace them if necessary.

WATER PUMPCheck water pump for free rotation. Check waterpump for flow rate at specified rpm. Check for waterleakage through leakage hole. It indicates that waterseal is damaged and leaking. Replace the waterpump if necessary.

Dismantling and repairing of water pump is notrecommended.

Fig. 95

Fig. 96

Checking of thermostat element

1. Remove thermostat element from thermostathousing.

2. Mount thermostat element in suitable fixtureand place the fixture in a vessel filled withwater.

3. Fix dial gauge with its spindle on valve surfacewith a pretension @ 0.5 mm.

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4. Heat the vessel and measure water temperaturewith thermometer.

5. Note down the temperature when dial gaugeneedles starts moving indicating valve opening.

6. Opening temperature and fully open temperaturemeasured should be as mentioned in repairdata.

If they do not meet specifications, replace thermostatelement.

INSPECTION OF TIMING BELT

Check belt in detail. If following flaws are evident,replace belt with new one.

- Back surface glossy, non elastic and so hard thateven if finger nail is forced into it, no mark isproduced.

- Cracked back surface rubber

- Cracked or exfoliated canvas

- Cracked tooth bottom

- Side of belt cracked

- Side of belt badly worn

- Badly worn teeth

- Missing tooth

It is advisable to replace belt while reconditioning theengine.

NOTE:

Normal belt should have clear cut sides, as if cut witha sharp knife.

In initial stage of wear, load side tooth flank will looklike fluffy canvas fiber, rubber gone and colour changedto white.

In last stage of wear, canvas on load side tooth flankwill be totally worn out exposing rubber.

ASSEMBLY OF CYLINDER HEAD

Install valves in their respective positions.

Install spring seat, valve spring and valve retainers.

Fit support rail, 2654 5890 05 06 on cylinder head.

Fig. 97

Fig. 98

With spring compressor, 2654 5890 05 07 compressvalve spring and install valve lock halves. Refer Figure97

In case of any replacement of tappet/valves ormachining of valve seat use thinnest size of shims.

Install original or thinnest size shims in their respectivepositions. Refer Figure 98

Apply light coat of moly paste grease over shims.

Smear tappet outside diameter with engine oil.

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Install tappets in their respective positions. ReferFigure 99

Smear Cam shaft journals and cam lobes withmoly paste grease.

Install cam shaft with arrow mark pointing towardsengine front. Refer Figure 100

Install cam shaft bearing caps in their respectivepositions with arrow mark pointing towards enginefront.

Apply ANABOND 610 sealant on parting facesbetween 1st & 5th cap and cylinder head.

Tighten cam shaft bearing cap nuts with NEWWASHERS to specified torque (first 3rd cap, next4th and 2nd caps, lastly 5th and 1st caps). ReferFigure 101

Fig. 99

Fig. 100

Fig. 101

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Check cam shaft axial play. It should be withinspecified limits. Refer Figure 102

Check camshaft for rotation, the frictional torque shouldbe between 1.8 to 2.2 mkg. Refer Figure 103

Install wood ruff key and cam shaft gear. Tighten camshaft gear mounting screw along with spacer. ReferFigure 104

Fig. 102

Fig. 103

Fig. 104

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VALVE CLEARANCE

Valve clearances should be checked only when engineis cold.

Turn cam shaft with spanner, 2654 5890 05 01 andcheck valve clearances. Refer Fig. 105

Adjust as given below:

Note respective valve clearances.

Calculate correct sizes of shims (Shims are availablein thickness 2.4 to 3.55 mm in steps of 0.05 mm) toget specified valve clearances as shown in followingtable.

CALCULATION INLET EXHAUST

Specified 0.15 +0.04 0.3 +0.04

Measured 0.25 0.2

Difference + 0.1 - 0.1

Existing shim thickness 2.8 3.05

Shim thickness required 2.9 2.95

Smear moly paste on both sides of shims.

Install all eight correctly determined size shims in theirrespective positions.

Recheck valve clearance and if incorrect repeat aboveprocedure.

Remove camshaft gear.

Fitment

Install cam shaft front and rear oil seals using adapter,2654 5890 05 08. Refer Figure 106

Fig. 105

Fig. 106

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Fit

Injectors with flame guard, new flame guard washerand sealing washer. Refer Figure 107 (Convex side ofthe flame guard washer should be up while installation)

Tighten injectors to specified torque using socket,

312 589 00 09. Refer Figure 108

Injector over flow hoses. Refer Figure 109

Glow Plugs.

Fig. 107

Fig. 108

Fig. 109

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ENGINE ASSEMBLY PROCEDURE

Fit piston Cooling nozzles.

Fit drive shaft spigot bearing and oil pump drivesprocket gear on crankshaft using suitable drift.

Install thrust washers in crankcase at theirrespective location on 4th Main bearing sides.

Apply light coat of engine oil to main bearing shellsand main journals. Install main bearing shells oncylinder block.

Install crank shaft.

Install thrust washer on 4th main bearing cap sides.

Install 4th main bearing cap with shells and thrustwasher in its position on crank case.

Install 1st, 2nd and 3rd main bearing caps withshells in their respective position on crank case.

Clean the grooves of 5th main bearing cap andmake it free from oil and grease.

Apply a thin layer of maxifix adhesive-S758(Dunlop make) in the groove and allow it to dry for10 minutes.

Assemble both the side seals on 5th main bearingcap - Refer Figure 110 avoiding air bubbles andpress firmly. Cut off the extra length of side sealkeeping 2 mm projection above cap height.

Apply ANABOND 611 between mating faces of 5thmain bearing cap and cylinder block.

Install 5th main bearing cap with shell and sideseal in its position on crank case.

While installing ensure that

- Side seals are not getting cut or dislodged fromits position on 5th main bearing cap.

- Thrust washers are not dislodged from theirseat in crank case and 4th main bearing cap.

- Bearing shell lugs are on same side.

Tighten main bearing cap mounting bolts evenlyand uniformly to specified torque. (First 3rd cap,next 4th and 2nd, lastly 5th and 1st) Refer Figure111

Check that end float of crank shaft is withinspecified limits. Refer Figure 112

Fig. 110

Fig. 111

Fig. 112

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Install rear oil seal using drift, 2654 5890 03 04.Refer Figure 113

Locate flywheel on crank shaft rear flange.

Install locking plates and screw-in flywheel mount-ing screws.

Tighten flywheel mounting screws to specifiedtorque. Refer Fig. 114

Lock them by bending lock plates. Refer Fig. 115

Remove connecting rod bearing cap with shell.

Insert connecting rod in piston such that combus-tion cavity on piston and bearing shell lugs on con-necting rod are on same side. Refer Figure 116

Fig. 114

Fig. 115

Fig. 116 Fig. 113

57

4 DLTC ENGINE

Insert piston pin. Fit piston pin spring clip

Refer Figure 117

Top surface of all rings are identified on top surfaceby etching mark 'TOP'. Assemble rings with etchingmark 'TOP' facing up.

Make sure that ring gap are 120 degrees apart toeach other. Make sure that none of the ring gapsfall directly on piston pin axis.

Apply oil on piston, piston rings, cylinder bore andbearing shells.

Turn crank shaft and bring crank pin journal to topmost position onto which connecting rod with pistonis to be fitted.

Insert connecting rod with piston upto piston ringsinto cylinder bore with arrow on piston crown pointingtowards front. Clamp piston ring compressor overpiston rings such that piston with piston rings canslide inside it. Refer Figure 118

Push piston gradually inside cylinder bore usingwooden handle or mallet till connecting rod locateson crank pin journal. Slowly rotate crank shaft,simultaneously pushing piston till crank pin journalreaches BDC position.

Install connecting rod bearing cap with bearing shellon connecting rod ensuring that bearing shell lugsare on same side.

Tighten connecting rod bearing cap mounting nutsto specified torque. Refer Figure 119

Fig. 117

Fig. 118

Fig.119

58

4 DLTC ENGINE

Assemble other connecting rods with piston in samemanner.

Check end play of Con-rods. Refer Figure 120

* Apply liquid gasket ''Anaerobic liquid gasket TS25408'' (Code No. 56506002520) uniformly betweencylinder block and ladder frame mating surfaces.

Fit the ladder Frame.

Install oil pump drive chain over oil pump drivesprocket gear on Crankshaft.

Install crank shaft front oil seal using drift, 26545890 03 03. Refer Figure 122

Fit crank case front cover with new gasket. Tightenscrew to specified torque . Refer Figure 123

Fig. 121

Fig. 122

Fig. 123 Fig. 120

59

4 DLTC ENGINE

Fit oil sump with new gasket. Tighten mounting screwsto specified torque. Refer Figure 124

Install -

- Power steering pump mounting bracket.

- A/C Compressor mounting bracket. Refer Figure125

- Water pump.

- Oil cooler assembly.

- Oil filter. Refer Figure 126

Install

- Timing gear train rear cover.

- Idler roller.

- Fan mounting bearing block.

- Tensioner roller.

Install both wood ruff keys in position. Slightly tapcrankshaft gear and push it over crankshaft.

Install crankshaft pulley in position.

Lock fly wheel with timing pin, 2654 5890 03 09.Refer Figure 127

Fig. 124

Fig. 125

Fig. 126 Fig. 127

60

4 DLTC ENGINE

Fig. 130

Screw in crankshaft pulley mounting bolt with spacerand tighten it to specified torque. Refer Figure 128

Measure piston projection above crank case andselect correct thickness of cylinder head gasket.

Refer repair data.

Rotate cam shaft and bring valves of 1st cylinderto compression TDC position. Refer Figure 129.

Procedure for selection of cylinder head gasket :

- Place adaptor with dial gauge on a surface block& set reading on dial gauge to zero.

- Rotate crank shaft to TDC and place the adaptoron cylinder no. 1 with adaptor touching crankcase top face and dial gauge touching pistontop (make sure that it is not touching the pistoncavity). Take the reading of piston projection.

- Repeat the same procedure for cylinder no. 4 &take the reading.

- Rotate crank shaft by 180O and repeat the aboveprocedure for cylinder no. 2 & 3.

- Select head gasket based on highest readingobtained from all 4 piston projections. Gasketselection should be done as per procedure givenin repair data.

Ensure that cylinder head locating hollow dowel isin position on crank case.

Ensure that timing pin. 2654 5890 03 09 is installedin position.

Install cylinder head and tighten cylinder headmounting screws to 5 mkg torque in the correctsequence i.e. from centre to outwards. Then retightenscrews to 7 mkg torque in the same sequence.

Then tighten to 10.5 mkg torque. Refer Figure 130

Fig. 128

Fig. 129

61

4 DLTC ENGINE

Fig. 131

Fig. 132

Fig. 133

Thickness Identification No. punched at this location on the gasket. (1.5 mm thick : 60-33155-40 , 1.6 mm thick : 60-33155-50)

Rivet

Rivet

Rivet

Rivet

Multi Layer Steel (MLS) Cylinder head gasket :MLS gasket make Reinz, Germany has beenintroduced on 4 DLTC engines (Euro I, Euro II &Euro III) for robust sealing system.

Please refer figure no. 131a

Presently it is available in 1.5 mm thick & 1.6 mmthick.

Rivets (4 nos.) have been provided on gasket forproper location of gasket.

Cylinder block and cylinder head has been suitablymodified for relieving of rivets at 4 locations.

In addition to this slit width in cylinder block hasbeen changed to 1.6 mm -0.1 mm from 2.0 mm-0.2 mm

MLS gasket can not be fitted on old type cylinderblock.

There is no change in cylinder head mounting boltand tightening torque of head bolts.

Please ensure to use appropriate cylinder block,head gasket and cylinder head during repairs.

Fit belt tensioner locking screw and timing gear trainrear cover mounting screw at cylinder head.

Install wood ruff key, cam shaft gear and spacer.

Tighten cam shaft gear mounting screw to specifiedtorque. Use special tool 2654 5890 05 01. ReferFigure 131

Fit- Inlet manifold. Refer Figure 132

- Exhaust manifold. Refer Figure 133

Fig. 131 a

62

4 DLTC ENGINE

Fit

- Turbocharger

- Turbocharger exhaust elbow / pipe

- Oil connection to turbocharger. Refer Figure 134

- Starter motor assembly. Refer Figure 135

- FIP mounting bracket

- FIP

Install wood ruff key in its position.

Install fuel injection pump gear.

Tighten fuel injection pump gear.

mounting nut to specified torque. Refer Figure 136 Fig. 134

Fig. 135

Fig. 136

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4 DLTC ENGINE

Lock camshaft gear with timing bolt 2654 5890 0502 Refer Figure 137

This will ensure compression T.D.C. position of 1st

piston.

Lock FIP gear with timing bolt, 2654 5890 05 02Refer Figure 138

Using drive square pt no. 2654 5890 0510 movetensioner roller and tighten tensioner locking bolt.

Install timing belt over crank shaft gear. Keep itstretched and slip over idler roller, fuel injectionpump gear, camshaft gear tensioner roller and waterpump gear.

Loosen tensioner locking bolt slightly and after rollerexerts tension on timing belt, tighten it fully.

Refer Figure 139.

Fig. 137

Fig. 138

Fig. 139

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4 DLTC ENGINE

Remove timing bolts and timing pin

Rotate crank shaft with spanner 2654 5890 03 02by full two turns in direction of engine rotation.

Refer Figure 140

Try fitting timing bolts and timing pin in its position.If it is not possible to fit any one, repeat timing belt

installation procedure from beginning.

Ensure that timing bolts and timing pin are removedafter timing belt fitment.

- FIP timing adjustment procedure is givenseparately. Connect engine stop solenoid and coldstart advance unit electrical cable to fuel injectionpump

Fit

- Cab heating valve unit (if fitted)

- Thermostat assy Refer Figure 141

- Oil separator and hoses

- FICD unit

- Fuel return pipe from FIP to fuel tank

- High pressure injection pipe from injectors to FIP

- Coolant pipe

- Over flow hose from 1st injector to fuel injectionpump

Install all three (front left, front right and front lower)timing gear train covers.

Lock front timing cover with clip and toggle clamps.Refer Figure 142

Fig. 140

Fig. 141

Fig. 142

65

4 DLTC ENGINE

Fit

- A.C. compressor assembly. Refer Figure 143

- Power steering pump. Refer Figure 144

- Alternator

Install fan pulley. Tighten castle nut and lock it withsplit pin.

Install fan along with hub. Tighten mounting screwsto specified torque and lock them with lock plates.Refer Figure 145

Install fan belt.

Adjust fan belt tension.

Fig. 143

Fig. 144

Fig. 145

66

4 DLTC ENGINE

F.I.P. TIMING SETTING PROCEDURE (MICO)

Ensure that timing pin is located in flywheel holethrough cylinder block rear wall.

Disconnect high pressure injection pipes frominjectors to fuel injection pump. Refer Figure 146

Slightly loosen fuel injection pump front mountingnuts and rear mounting taper nut.

Remove timing plug on fuel injection pump.Refer Figure 147

Fit timing adapter, 2654 5890 05 09 in place of timingplug. Refer Figure 148

Remove timing pin from flywheel.

Mount dial gauge in timing adapter with somepreload. Refer Figure 149

Fig. 147

Fig. 148

Fig. 149 Fig. 146

67

4 DLTC ENGINE

Tighten adapter cap nut.

Rotate crankshaft in anti-clockwise direction byapproximately 30 degrees.

Precisely locate bottom dead center of fuel injectionpump plunger by slight rotation of crank shaft ineither direction.

Set dial gauge reading to 0.

Rotate crank shaft clockwise to TDC position andinsert the timing pin in flywheel. Refer Figure 150

Slowly rotate fuel injection pump till plunger lifts byvalues given below in dial gauge. Rotating fuelinjection pump towards crank case increasesplunger lift and vice versa. Refer Figure 151. Forengines with MICO FIP.

Euro II engines 0.71 ± 0.02 mm

Euro I engines 0.83 ± 0.02 mm

Fully tighten fuel injection pump front mounting nuts,rear mounting bolt and taper nut in this position.

Remove timing pin from cylinder block.

Rechecking timing

Rotate crank shaft by two full rotations. Checkinjection pump plunger lift as specified above.

In this position it should be possible to insert timingpin in flywheel. If not, repeat fuel injection timingadjustment procedure.

Remove dial gauge and timing adapter, 2654 589005 09. Refer Figure 152

Fit back timing plug on fuel injection pump.

Connect high pressure injection pipes to fuelinjection pump. Refer Figure 153

Fig. 151

Fig. 152

Fig. 153 Fig. 150

68

4 DLTC ENGINE

ELECTRICALLY OPERATED AUTOMATIC KSB :

(applicable for MICO FIP - Euro II)

FIP has got an automatic KSB (cold start accelerator)

operated by a 12V power supply. Control device (1)

Contains a wax module which is connected to KSB

control lever (2) through a cable (3). When engine is

running, control device draws current from battery

through solenoid (4). Current drawn from battery is

used to heat the wax module and the expanded wax

releases KSB control lever (which is held against a

torsion spring) towards the ‘ZERO’ position of injection

advance unit plunger through the connecting cable

(3). In this position, KSB control lever rests against a

stop plate (5) fitted in pump housing.

When current supply is cut OFF to KSB unit, wax

solidifies and control lever is pulled back to advanced

position (max. 2.5 deg. cam angle). This ensures

automatic timing advance during engine start. It is to

be noted that during engine running, power supply to

KSB control device is on.

Setting static timing on FIP fitted with KSB unit.

After fitting FIP loose on engine, 12V power supply to

be connected to KSB control device to ensure that

KSB control lever rests against stop plate. This takes

3 to 4 minutes after giving supply. This corresponds

to fully retarded position of advance unit plunger.

At this position, specified lift of pumping plunger to

be set atTDC of the engine and pump mountings to

be tightened.

Temperature controlled idle speed increase (TLA) :

(applicable for MICO FIP)

Above pump has also got the feature TLA. TLA is

likewise actuated by control device (1). For this

purpose, KSB control lever (2) is extended and a ball

pin (6) is fitted. When engine is started in cold, this

ball pin presses against the speed control lever and

lifts it off the idle stop screw (7).

Idle speed is thus increased and engine warm up is

improved. By the time engine is warm, KSB control

lever is against KSB stop plate. Consequently, speed

control lever also rests against idle stop screw

ensuring normal idling.

69

4 DLTC ENGINE

6

13725

4

KSB CONTROL DEVICE TERMINAL

SPEED CONTROL LEVER

Fig. 154

1 - Control device2 - KSB control lever3 - Cable4 - Stop soleniod5 - Stop plate6 - Ball pin7 - Idle stop screw

70

4 DLTC ENGINE

Fig. 155

Principles of DPC pump operation & HydraulicCircuit with Boost Control

Fuel system consists of fuel tank, fuel filters, fuelinjection pump and injectors.

Fuel is drawn into fuel injection pump by the transferpump through filter assembly. A hand primer fittedbetween tank and filter facilitate in filling and ventingoperations.

Return line from FIP and injectors is connected totank thus forming a closed loop system.

Transfer pump sucks fuel from tank, through filterassembly and increases the feed pressure andregulates it.

Fuel thus transfered and pressurised is metered by ametering valve and passes through electrical shut-offvalve.

LUCAS DPC FIP FOR EURO III ENGINES

Injector

HandPrimingPump

SecondaryFuel Filter

FIP

HP lines

Tank Cap WithBreather

Fuel returnline

FuelTank

Fuel Supplyline

PrimaryFuelFilter

Metered fuel passes through various drillings of head& rotor between pumping plungers in rotor.

Pumping plungers when depressed by the action ofthe opposed cam lobes, rise the pressure to muchgreater level and the fuel at high pressure flows to theinjectors.

71

4 DLTC ENGINE

Fig. 156

KEY

Feed pressure Atmospheric pressure

Transfer pressure Boost actuator pressure

Backleakage pressure Boost pressure

Metering pressure Cambox pressure

Injection pressure Advance control pressure

Alternate pressure feed-injection

Governorcontrol

Transferpump

Meteringvalve

InjectorCamboxpressurisingvalve

Auto advancemechanisum

Electrical coldidle advance

BoostController Boost

pressure

TP regulatingvalve

Shut offsolenoid

Cambox

Fuel tank

Fuel filter

LUCAS DPC FIP - HYDRAULIC CIRCUIT

72

4 DLTC ENGINE

Fig. 157 Lucas - FIP (Euro III) side view

LUCAS FIP - EURO III

Fig. 158 Lucas FIP (Euro III) Top view

PLLA

Drive Shaft

Boost Controller

Cold Idle Advance

EGR ThrottleSwitch

Anti-stallscrew

Idling Screw

73

4 DLTC ENGINE

LUCAS DPC FIP - FEATURES

1. EXCESS FUEL SYSTEM

To assist engine starting, excess fuel system providesat very low pump speeds, fuel delivery that is greaterthan full load delivery.

The system is incorporated in delivery controlmechanism, which by the action of a return springallows distance between the pumping plungers to beincreased to a level that is more than normal operatinglevels. This increased outward travel of plungers allowextra quantity of fuel to flow in during filling cycle.The same is pumped out during pumping stroke.

As the Engine speed increases, increase in transferpressure automatically cuts-off excess fuel. Thetransfer pressure pushes delivery control systemagainst the opposing return spring to retain it in normaloperating position.

2. TWO SPEED GOVERNOR (MIN.-MAX.)

● Function of two speed governor is to control idling.Fast idling and maximum no-load speed ofengine.

● Governor interferes only during idling andmaximum no-load conditions, to determine theposition of metering valve and thus control fueldelivery.

- During intermediate phase, metering valve isdirectly linked to throttle lever (accelerator pedal),providing a direct control.

ADVANTAGES :

● Smooth response to alterations in throttleposition.

● Improved driveability.

3. PROGRESSIVE LOW LOAD ADVANCE (PLLA)

Low Load Advance System overrides normal speedadvance system. Under low load conditions, due toreduced fuel supply, there is a tendency for the timingto retard. Low load advance system compensatesfor this characteristic by slightly advancing injectionat reduced fuel levels.

Type of low load advance system used is calledprogressive low load advance (PLLA) system.

Advantage of PLLA system is, that it progressivelychanges the advance to suit engine load conditions.Thus helps in achieving better emissions and alsoreduces transient noise.

5. BOOST CONTROLLER (Fig 155e)

Boost Controller is necessary on FIP fitted to turbocharged applications, in order to adjust maximum fueldelivery in accordance with variations in boostpressure from turbo charger.

Fuel adjustment plate and roller shoes on the pumpare provided with ramps to allow for progressivechange in fuel delivery as the assembly move axiallyon the rotor by the action of the actuating pistonmoving against a carriage return spring.

Boost controller consists of a piston valve movingwithin a valve body. The valve is linked to a pair of

Fig. 159

Backleak return

Boost pressure inlet

Piston

Dischargeto transferpump inlet

Valve bodyFueladjustingscrew

Spring

Spacer

Diaphragms

4. SUPPORTED TOOTHED BELT TYPE DRIVE

● Assembly consists of drive shaft assemblysupported by two bearings and in the pumphousing the shaft is connected to the pumphydraulic head by an intermediate shaft.

● Bearing opposes the loading created by drivebelt, thus maintaining alignment of drive shaftand hydraulic head.

ADVANTAGES :

● Smoother Running

● Pumping drive draws lesser power from engine

● Noise reduction

74

4 DLTC ENGINE

diaphragms within boost controller. Boost pressure ispiped and connected to the chamber formed betweentwo diaphragms. Diaphragms sense variation in boostpressure and maintain the balance between fueldelivery and boost pressure, by continuously varyingthe pressure behind actuating pistons.

Operation :

At cranking speeds, assembly is held in Excess Fuelposition (Full Boost) by a spring. As the engine picksup, transfer pressure builds up behind the actuatingpistons and moves the assembly to minimum fuelposition.

As boost pressure increases with the rise in enginespeeds, the diaphragm responds and allows thepressure to leak acting behind actuating pistons. Thisallows the return spring to move the assembly axiallytowards increased fuel delivery position.

6. EGR THROTTLE SWITCH

EGR Throttle Switch fitted on throttle lever is used tosense the position of throttle lever. The output is givenEGR controller.

7. COLD IDLE ADVANCE

Solenoid operated Cold Idle advance is driven by glowplug timer (GPT) and overrides normal advance controlmechanism when engine is cold. This normallyfunctions in conjunction with engine Pre / Post heatsystem and operates only when electrical input issupplied to it by GPT.

AIR VENTING

DPC pumps are self venting pumps and thereforeallows air entering into it, to go out through return line.However, it is recommended that whenever fuel linesare disconnected, system is to be primed in order tofill the system with fuel and remove air present in thesystem completely.

Procedure

● Energise Fuel Shut-Off Solenoid (Switch 'ON'ignition switch).

● Loosen following vent screwsOn the banjo bolt at filter outlet �On the FIP timing chimney plug �(See fig. 160)

● Loosen priming pump plunger � and actuate thepump until clear fuel comes out of vent screw �

● Tighten vent screw �

● Continue actuating priming pump plunger until clearfuel is seen coming out from vent screw �

● Tighten vent screw � and then priming pumpplunger �Loosen one of the HP connections at injectorend. Crank engine for few seconds; and see thatfuel flows out of injector line. Tighten HPconnection.Start engine and see that there is no fuel leakfrom any points/connections.

Fig. 160

2

1

3

75

4 DLTC ENGINE

IDLE SPEED SETTING

Procedure

1. Setting 'Idle' speed :

1.1 Set when the engine is hot.

1.2 Slacken lock nut �, and turn the idling screw �Fig. 161, to set idling speed as specified.

1.3 Tighten lock nut � Fig. 161, and re-check idlespeed.

2. Setting Fast Idle Control Device :

2.1 Fast Idle Speed as specified can be adjusted bysetting the stroke length of Fast Idle ControlDevice.

2.2 Slacken lock nut �, and adjust stroke length ofFICD by turning adjuster � Fig.161

2.3 Hold adjuster and tighten lock nut.

2.4 Re-check the setting speed.

Specified value

Idling speed : 850 to 900 rpm

Fast idle speed : 950 to 1000 rpm

Fig. 161

1

4

3

2

76

4 DLTC ENGINE

ANTISTALL SETTING :

4 Move throttle lever by approximately 2.0mm.Speed should increase from idle speed. If notadjust antistall in the direction of throttle travelas required.

5 Move throttle lever to near full throttle positionand release. The die-down time should bemaximum 4 seconds without any undershoot(speed reducing below idle speed and jerk /vibration observed). If it is more than 4 secondsmove antistall screw in the direction of the driveend as required. If undershoot is observed movein the direction of throttle travel.

6 Verify and confirm that idle speed has not beendisturbed. If idling found to be disturbed, repeatantistall setting procedure (steps 4 to 7).

● Don’ts

Do not try to adjust / set idle speed with antistallscrew.

Fig. 162

Drive End

Idling Screw

Antistall screw

Direction of throttle travel

Procedure

● This is set to prevent vehicle stalling whenaccelerator pedal is suddenly released fromdepressed position

● Setting is achieved by optimizing between deadtravel and die-down time.

● Verifying / Adjusting Antistall setting

1 Warm the engine sufficiently to ensure thatthermostat is open and engine is free to rotate.

2 Air-conditioning should be in off position. No otherexternal loads (like power steering, alternatorloads) should be imposed on engine.

3 Check idling speed. Adjust the same using idlingscrew to specified value, if required. (850-900rpm).

77

4 DLTC ENGINE

Lucas DPC FIP – 254707100138(For Telco Line & Safari – Euro 3)

�

�

DTVS Part No Description Telco Part No Iden. NoG8473B200A Fuel Injection Pump 254707100138 �

9108-073A Solenoid assy 254707990147 �

9103-287 Inlet copper washers 254707999901 �

9007-392A Back leak valve copper washers 254707999902 �

�

�

SERVICEABLE PART LIST FOR LUCAS DPC FUEL INJECTION PUMP

Lucas DPC FIP – 2547 0710 0137 (For Telco Line and Safari – Euro 2)

�

�

�

�

DTVS Part No Description Telco Part No Iden. NoG8473B101B Fuel Injection Pump 254707100137 �

9108-073A Solenoid assy 254707990147 �

9103-287 Inlet copper washers 254707999901 �

9007-392A Back leak valve copper washers 254707999902 �

78

4 DLTC ENGINE

�

Delphi-TVS Filter Assembly – 254709110118(For Telco Line and Safari Euro 2 & Euro 3)

�

��

�

�

��

DTVS Part No Description Telco Part No Iden. No

G6300B040A Filter assy 254709110118 �

9183-012A Filter head 254709999901 �

9188-005Filter element (7111-296) 254709999902 �

9183-120 Hand primer 254709999903 �

9188-004 Assy. Base filter 254709999904 �

9007-864 Bolt banjo 254709999905 �

9007-383A Washer 254709999906 �

5334-332C Vent screw 254709999908 �

9188-003 Assy. Bolt banjo 254709999907

7111-740 Assy. Plug 254709999909

Delphi-TVS Injector Assembly – 2547 0116 0111 (Telco Line and Safari – Euro 2 & Euro 3)

�

�

Delphi-TVS Part Number

DescriptionTelco Part

NumberIdentification

NumberG02001G Injector assy '254701160111 �

9008-088WAssy Nozzle (R5643493) 254701999902 �

SERVICEABLE PART LIST FOR LUCAS DPC FILTER & INJECTOR

79

4 D

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Cause Check

1. Lack of Fuel 1 Fuel Level

2. Manual stop control* faulty 2. In run position and linkage free

3. Stop solenoid* faulty 3. Audible operation when switched. Check electrical supply.

4. Stop solenoid* valve leaking 4. Engine stops when supply lead removed.

5. Wrong starting procedure 5. Starting procedure correct. (Start advance and starting aid operation).

6. Air in fuel system 6. Fuel System is vented, all joints and unions airtight, no leakage at diaphragms

7. Fuel inter restriction 7. Filter not choked and feed pipes clear

8. Fuel contamination 8. Diesel fuel being used, not petrol; free of water, dirt, ice and wax

9. Low viscosity / low density fuel 9. Check for origin of fuel

10. Low cranking speed 10. Battery, Starter, Cable Connections, Correct engine lubricating oil

11. Starting aid* ineffective (Plugs or Thermostart) 11. Correct functioning. Fuel supply* timer* and electrical connections

12. Injection timing incorrect 12. Pump to engine timing

13. Timing belt* slipped several teeth 13. Belt / Chain condition and tension

14. Feed pump* faulty 14. Feed Pump Pressure

15. Fuel return restricted 15. Rotary pump backleak, tank returns, filter vents are clear

16. Fuel circuit incorrect 16. Inlet and backleak pipes correct way round. Banjo bolts of correct Lucas-TVS type

17. Engine condition 17. Cylinder compression. Valve timing and clearances. Air filter not choked, Injector seating

18. Exhaust system defective 18. System Unrestricted

19. Fuel atomisation 19. Injectors : correct type, opening pressure, spray conditions, evenly tightened

20. Fuel tank blockage 20. Tank vent and outlet filter unrestricted

21. HP Pipe type / firing order incorrect 21. HP Pipes type and fitted in correct firing order

22. HP Pipe restriction 22. HP Pipes not kinked or bore reduced at nipples

23. HP vent* leaking 23. Vent screw tight

24. HP Pipe leaking 24. HP Pipe joint tightness

25. LP Leakage 25. Feed and return pipe, filter, feed pump and tank for leakage

26. Idling speed incorrect 26. Idling speed

27. Anti-stall* setting incorrect / high 27. Recovery from acceleration, engine warm (if necessary, reset idling and anti-stall)

28. Maximum speed setting incorrect 28. Engine fly-off (maximum.) speed

29. Throttle lever not returning to min position 29. Check for stickiness of throttle lever / PLLA lever

30. Accelerator linkage faulty 30. Throttle lever tight on pump and reaches stop screws. Linkage wear, adjustment, free movement

31. Engine Vibration 31. Engine mountings tight and effective

32. Vibration 32. Vibrations transmitted to engine (e.g. from gear box)

33. Overloading 33. Vehicle payload

34. Vehicle brakes binding 34. Brake freedom wheel by wheel, handbrake off

35. Injection pump mountings loose 35. Tightness of pump drive mounting bolts.

36. Injection pump defective 36. If all other relevant checks are satisfactory, remove pump for specialist check at Delphi-TVS* If fitted Authorised Centre

FAULT DIAGNOSIS FUEL INJECTION SYSTEM

Symptom

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●●●●● ●●●●● ●●●●● ●●●●● ●●●●● ●●●●●

●●●●● ●●●●● ●●●●● ●●●●● ●●●●●

●●●●● ●●●●●

●●●●● ●●●●● ●●●●● ●●●●● ●●●●●

●●●●● ●●●●● ●●●●●

●●●●● ●●●●●

●●●●●

●●●●● ●●●●● ●●●●● ●●●●● ●●●●●

●●●●● ●●●●● ●●●●●

●●●●● ●●●●●

●●●●●

●●●●● ●●●●● ●●●●●

●●●●● ●●●●● ●●●●●

●●●●● ●●●●● ●●●●● ●●●●● ●●●●● ●●●●● ●●●●● ●●●●● ●●●●● ●●●●● ●●●●●

80

4 D

LTC

EN

GIN

EB

ack

Leak

age

Ope

ning

Pre

ssur

e

Ato

mis

atio

n

Sea

t Tig

htne

ss

Cyl

inde

r Kno

ck -

Une

ven

Run

ning

- M

isfir

e

Loss

of P

ower

- E

xces

sive

Con

sum

ptio

n

Eng

ine

Ove

rhea

ting

Bla

ck S

mok

e

Poo

r Sta

rting

Cause Check

1. Injector not sealing in cylinder head 1. For cleanliness and sealing washers; if specified

2. Two sealing washers under injector 2. Number of washers and if specified

3. High pressure pipe joint leaks 3. Pipe unions for leaks

4. Back leak pipe joint leaks 4. Unions for leaks

5. High Pressure pipe restricted 5. High pressure pipe bores

6. Injector / Nozzles Sticky 6. Fixing nuts tightened / injectors screwed in to the correct torque, fuel contamination/ adulteration, dirt / burrs / debris in HP pipes

7. Incorrect injectors fitted 7. Manufacturer's specification

8. Injector Faulty 8. Check injector on a nozzle setting outfitAuthorised Centre

FAULT DIAGNOSIS INJECTORS

Symptom

●●●●● ●●●●● ●●●●●

●●●●● ●●●●● ●●●●● ●●●●● ●●●●●

●●●●● ●●●●● ●●●●●

●●●●●

●●●●●

●●●●● ●●●●● ●●●●● ●●●●● ●●●●●

●●●●● ●●●●● ●●●●● ●●●●● ●●●●●

●●●●● ●●●●● ●●●●● ●●●●● ●●●●●

Removing Injectors : Always ensure that injectors are not knocked during removal particularly pintle nozzles as the valve tips can easily be damaged.Impact extractors to be used for flanged / clamped injectors.

Fitting Injectors : Ensure Injector, cylinder head bore and seat are clean. Ensure manufacturer's specification is observed for fitment of sealingwasher and heat shield. Tighten fixing bolts or nuts evenly to the correct torque.

If nozzle body or valve is worn or damaged the nozzle must be replaced or sent for specialist repair, to Delphi-TVS Authorised Centres.

Cause Check

1. Pressure face leak 1. Nozzle cap nut torque and pressure faces clean and undamaged

2. Nozzle valve scored or having excessive clearance 2. Valve stem and nozzle body visually

3. Incorrect setting 3. Opening pressure and reset if necessary

4. Nozzle seized or sticking 4. For foreign matter, distortion or damage

5. Spray holes blocked 5. Holes are free of carbon

6. Valve not seating 6. Nozzle valve and body for carbon pitting or damage

7. Broken or distorted spring 7. Spring visually and replace if necessary

8. Auxiliary hole blocked 8. Hole is free of carbon

9. Pintle broken or damaged 9. Nozzle valve tip visually for damage

10.Nozzle holder spindle worn 10. Spindle ends for wear and replace if necessary

11. Nozzle cap nut overtightened 11. Cap nut torque

Symptom

●●●●●

●●●●●

●●●●● ●●●●●

●●●●● ●●●●● ●●●●●

●●●●● ●●●●●

●●●●● ●●●●● ●●●●● ●●●●●

●●●●● ●●●●●

●●●●● ●●●●●

●●●●●

●●●●● ●●●●●

●●●●● ●●●●● ●●●●●

81

4 D

LTC

EN

GIN

E

Bla

ck /

Dar

k G

rey

at fu

ll lo

ad

Bla

ck /

Dar

k G

rey

at h

igh

load

Bla

ck /

Dar

k G

rey

any

load

Blu

e / W

hite

at l

ight

load

Blu

e at

ligh

t loa

d / a

ccel

erat

ion

Blu

e an

y lo

ad

Cause Check

1. Overspeeding 1. Maximum speed setting

2. Lub oil induction 2. Oil bath air cleaner for overfilling (Wherever fitted)

3. Choked Venturi 3. Venturi (Pneumatic Governor) is not restricted (Wherever fitted)

4. Retarded timing 4. Pump to engine timing, auto advance function

5. Incorrect atomisation 5. Injectors - see chart

6. Air Starvation 6. Air cleaner ducting restrictions; turbo operation

7. HP Pipes 7. Bore size; length; restrictions

8. Cold Engine 8. Thermostat : Cooling system, operation

9. EGR valve is permanently open 9. Functioning of valve, setting of EGR switch

10. Carbon deposition in intake system 10.Cleanliness of EGR valve, intake manifold

11. VSV valve not working properly 11.Vacuum connections to VSV and its functioning

12. Advanced Timing 12.Pump to engine timing; auto advance function

13. Poor Compression 13.Setting / condition of valves, piston rings + air intake

14. Overfuelling 14.F.I. Pump, excess fuel device

15. Incorrect Atomisation 15. Injector type / setting / condition

16. Poor combustion 16. Injector fitment

17. Retarded timing 17.Pump to engine timing; auto advance function

18. Lub oil passing pistons 18.Piston / ring/ bore condition

19. Lub oil passing valves 19.Valve stem / guide condition

FAULT DIAGNOSIS SMOKE

Symptom

●●●●●

●●●●●

●●●●●

●●●●●

●●●●● ●●●●●

●●●●●

●●●●●

●●●●●

●●●●●

●●●●●

●●●●●

●●●●●

●●●●●

●●●●●

●●●●● ●●●●● ●●●●●

●●●●●

●●●●●

●●●●●

●●●●●

Speed

Maximum

Medium

to

Maximum

Low to

Medium

All

82

4 DLTC ENGINE

F.I.P. TIMING SETTING PROCEDURE (LUCASPUMP)

1. Lock flywheel in TDC position (with FIP gear andcamshaft gear holes matched as per procedurefollowed for timing belt fitment) by insertinglocking pin 2654 5890 0309 through cylinderblock rear wall into flywheel.

2. Remove sealing plug on FIP located at the top.Refer figure. 163.

Insert timing rod Pt No. 2654 5890 06 01(Lucas part no. : 9190-212). Refer figure. 164

Fit assembly timing bracket Pt no. 2654 5890 0602 (Lucas part no. : 1804- 607) and dial gauge usingclamping screw provided on timing bracket. Referfigure 165.

Loosen high pressure pipe lines from FIP, if fitted.

For setting timing on vehicle, use assembly timingbracket Pt No. 2654 5890 0603 (Lucas part no. :1804-606).Refer figure. 166

Fig. 164

Fig. 165

Fig. 166 Fig. 163

83

4 DLTC ENGINE

3. Remove locking pin from flywheel (Refer figure167) and rotate crankshaft anticlockwise (asseen from the front) by about 30 degrees till dialgauge on FIP shows minimum reading. Set dialgauge to zero. Refer figure. 168

4. Loosen FIP mounting nuts and also the screwfor rear support for FIP.

5. Rotate crankshaft clockwise as seen from thefront to TDC position and lock it by insertinglocking pin in flywheel.

6. Rock FIP till, dial gauge on FIP reads 0.90+0.02

mm and tighten FIP mounting fastners. Thisvalue is same for Euro II & Euro III engines.

7. Remove locking pin and rotate crankshaftanticlockwise by maximum 2 (two) revolutions.(DO NOT rotate clockwise, to avoid damage totiming spindle and dial gauge). Recheck timingby rotating clockwise and refitting locking pin atTDC position. If timing is not within 0.90 +0.02 mm,repeat the procedure (from points 3 to 6) till thisis achieved.

8. Remove locking pin from cylinder block, timingbracket with dial gauge and timing spindle fromFIP. Refit sealing plug and tighten to 0.5 mkg,and connect high pressure lines. Refer figure.169. Bleed the system before starting engine.

NOTE :

DO NOT overtighten sealing plug to prevent damageto adaptor and its setting.

DO NOT interchange assembly banjo bolt fitted atfuel return line on FIP, to avoid changes in fueldelivery values & timing advance settings.

Fig. 167

Fig. 168

Fig. 169

84

4 DLTC ENGINE

TURBO CHARGER

Working Principle of Turbocharger

Power output from an internal combustion enginedepends on mass of the air and fuel quantity thatare available for combustion.

To increase engine horse power, more air forcombustion and more fuel have to be delivered.

In case of a naturally aspirated engine, powerincrease is obtained by increasing swept volumeor by raising speed.

Increasing swept volume, leads to larger andheavier engines that are expensive. Speed increaseinvolves considerable technical problems anddisadvantages like low mechanical efficiency,increased wear and tear and increase in noise etc.

Power increase with unchanged swept volume atsame engine speed can be obtained bysupercharging of engine.

Super charger delivers pre compressed air to enginecylinders i.e. engine intake pressure is higher thanatmospheric. In naturally aspirated engines intakepressure is slightly below atmospheric.

Turbocharger is one of the super charging devicesused in an engine. It makes use of thermal energyof engine exhaust gases to run a turbine which inturn drives a compressor to pressurise inlet air.

AIR TOINDUCTION MANIFOLD

COMPRESSORHOUSING

COMPRESSORWHEEL

AIRFROM

FILTER

TURBINEHOUSING

SHAFT &TURBINEWHEELASSEMBLY

GASES TOEXHAUST

PIPE

BEARING

BEARINGHOUSING

THRUSTBEARING

COMPRESSORBACKPLATE GASES FROM

FXHAUST MANIFOLD

Fig. 170

OIL OUTLET

OIL INLET

85

4 DLTC ENGINE

Engine

Wastegate Fig. 171

This feature in turbocharger consists of a bypassvalve built into turbine housing. Some part of theexhaust gas going to the turbine is bypassedthrough this valve.

This is as shown in the sketch. wastegatearrangement reduces high boost pressuredeveloped by compressor to the desired value,thus obtaining optimum engine performance withcontrolled peak cylinder pressure.

Intercooler : Intercooler is air to air heat exchangerused to cool compressed air from turbocharger priorto entry to inlet manifold. This increases the densityof air entering engine inlet manifold and helps inimproving engine power output, fuel efficiency andemissions.

Boost control device (FIP LDA)

During sudden acceleration, there is a time lag forturbocharger to supply air at desired pressure,sufficient for proper combustion. This causes heavyblack smoke till turbocharger attains desired speedand delivers air at required pressure.

To overcome this, a boost control device (LDA unit)is incorporated in fuel injection pump which isactuated by air pressure inside inlet manifold andcontrols fuel delivery in accordance with airpressure available in inlet manifold.

Maintenance of the turbocharger

There is no mechanical drive connection betweenengine and turbocharger.

No adjustments or repairs should be carried out onturbocharger.

In case of doubtful performance or difficultiesexperienced, get it checked by authorised agency.

Following precautionary measures should be takento obtain trouble free performance of turbocharger.

1. During regular engine inspection look carefullyfor any oil leakage at the oil inlet banjoconnection on bearing housing. Do not runengine unless leakage at this point is rectified.

2. Do not stop engine suddenly as it may damagerotor bearings. Allow engine to idle for sometime before switching it off. Similarly, do notrace engine suddenly and unnecessarily.

3. Since the speed of rotor assembly istremendously high, it must get clean filtered oil.

Air Suction

Compressor

Exhaust Turbine

Engine

Compressor

TurbineExhaust

Waste Gate

From Air Filter

To ExhaustPipe

To Engine

Inte

rcoo

ler

Cool Air

Ensure cleanliness of engine oil by adhering toregular schedules of engine oil and oil filtercartridge change intervals.

4. As unfiltered dust par ticles enteringcompressor may prove dangerous, make surethat there is no leakage in air intake systemand that air filter element is in good conditionand sealed perfectly.

Repair of turbocharger

We do not recommend servicing of turbocharger. Incase of unsatisfactory performance, a new unit hasto be fitted.

Fig. 172

Fig. 171

86

4 DLTC ENGINE

TURBOCHARGER TROUBLE SHOOTING

Number Problemcode

1 Engine lacks power

2 Black exhaust smoke

3 Excessive engine oil consumption

4 Blue exhaust smoke

5 Turbocharger noise

6 Cyclic sound from turbocharger

7 Oil leak from compressor seal

8 Oil leak from turbine seal

1 2 3 4 5 6 7 8 Cause Remedyx x Clogged air filter element Replace element

x x x x x x Obstructed air intake duct from Remove obstruction or replace damaged partscompressor to intake manifold as required.

x x x Obstructed air outet duct from Remove obstruction or replace damaged partscompressor to outlet manifold as required.

x x x Obstructed air intake manifold Remove obstructionx Air leak in duct from air cleaner Correct leaks by replacing seals or tightening

to compressor fastners as requiredx x x x x Air leak from compressor to Correct leaks by replacing seals or tightening

intake manifold fastners as requiredx x x x x Air leak at intake manifold to Replace gaskets or tighten fastners as required

engine jointx x x x x x Obstruction in exhaust manifold Remove obstructionx x x Obstruction in exhaust system Remove obstruction or replace faulty

component as requiredx x x Gas leak in exhaust manifold to Replace gaskets or tighten fastners as required

engine jointx x x x Gas leak in turbine inlet to Replace gaskets or tighten fastners as required

exhaust manifold jointx Gas leak in ducting after Repair leak

turbine outletx x x x Obstructed turbocharger oil Replace gasket or tighten fastners as required

drain line Repair leakx x x x Obstructed engine crankcase Remove obstruction or replace line as required

ventilation Clear obstructionx x x x Turbocharger centre housing Change engine oil & oil filter

sludged or chocked Replace turbo if requiredx x Engine camshaft timing Rectify

inoorrectx x x x x x Worn engine piston rings or Rectify

liners (blow by)x x x x x x x x Dirt on compressor wheel Clean using a non-caustic cleaner & soft brush.

Find source of unfiltered air & change oil / oilfilter

x x x x x x x x Damaged turbocharger Analyze failed turbocharger, find correct causeof failure. Replace turbocharger as required

87

4 DLTC ENGINE

2.1 Catalytic converter maintenance / serviceprecautions

Catalytic convertor :

Telcoline with Euro-II/Euro-III engine is fitted witha two way Diesel oxidation catalytic converter toreduce exhaust pollution. Catalytic converter hascoating of precious metals which enablesconversion of pollutants.

Care of the catalytic Converter :

Catalytic converter does not require any specialmaintenance. However following precautions shouldbe taken for the effective functioning of converterand to avoid damage to converter.

● It is mandatory to use diesel as specified byus to meet emission level as per regulations.Use of inappropriate diesel can increasepollutants and damage Catalytic converter.

● Avoid parking the vehicle over inflammablematerials such as dry leaves, grass, etc.,as exhaust system can be hot enough toinitate ''FIRE''

Maintenance of Catalytic converter :

Catalytic converter should be flushed daily bygiving full throttle 4 to 5 times in vehicle stand stillposition.

In addition to this it is recommended to run vehicleat high speeds (60 to 80 kmph) for few kms. Thiswill help to flush carbon soot deposits fromexhaust system and catalytic converter. Highspeed running of vehicle is helpful to clean upCatalytic converter for deposits, if any.

Alternatively catalytic converter can be removedfrom vehicle and cleaned by dry compressed airdraft 3 to 4 bar. Compressed air has to be directedon honey comb structure for this purpose.

88

4 DLTC ENGINE

EGR SYSTEM (If fitted)

Fig. 173 Schematic diagram of EGR circuit on Euro - III Engine

Exhaust Gas Recirculation

TATA 4DL Turbo Inter-Cooled engine (Euro III) isequipped with an Exhaust Gas Recirculationsystem. This is to reduce exhaust emissions(mainly Nitrogen Oxides). Refer schematicdiagrams of EGR circuit.

In this system a controlled quantity of exhaust gasis re-circulated in to Inlet-manifold via EGR Valvein part load & part speed conditions.

Induction of exhaust gas into intake air results incontrolled combustion, thereby reducing NitrogenOxides emissions.

During cold starting till the glow plug remains on, EGRsystem does not function thus avoiding any huntingor vibration at initial start conditions.

System Components

EGR CONTROLLER :

EGR system is controlled more precisely based onengine speed, throttle lever position.

EGR CONTROLLER is mounted on the firewall insideeingine compartment.

EGR Valve (EGR-V)

EGR valve is a diaphragm valve that is actuated byvacuum from Vacuum Pump. This valve is mountedon air inlet manifold. It has three connections, one forvacuum, one for exhaust gas inlet from exhaustmanifold and one for the exhaust gas outlet to air inletmanifold. Exhaust gas starts flowing into inlet manifoldonce the vacuum is fed into valve.

EGR Electro pneumatic solenoid switch

Note : Care should be taken to connect the ports ofthe Electro pneumatic solenoid switch to theirrespective hoses. Any interchanging of connectionswill lead to malfunctioning of EGR system.Additionally, existence of small filter with foam needsto be ensured on the connection open to atmosphere.

EGR pipe :

This pipe connects exhaust manifold to EGR valve.

Exhaust / Inlet Manifold

Exhaust manifold has a precisely machined holethrough which the exhaust gas is tapped out.

VENT TO ATMOSPHERETHROUGH FILTER

Schematic diagram of EGR Circuit for 4 DLTC Euro III Engine :

89

4 DLTC ENGINE

ASSEMBLY :

EGR valve and EGR tube to be assembled as perfollowing instructions :

1. Hand tighten EGR tube flange to exhaustmanifold with respective fasteners.

2. Locate EGR tube and clamp on EGR valve.

3. Assemble EGR valve on Inlet Manifold andtighten it with respective fasteners.

4. Tighten clamp connecting EGR valve and tube.

5. Tighten EGR tube flange to exhaust manifoldwith respective fasteners.

Removal of EGR valve & EGR tube

Follow the reverse sequence of assembly.

Fig. 173 Schematic diagram of EGR circuit on Euro - III Engine

Inlet manifold also has a precisely machined holethrough which exhaust gas is fed into engine. Manifoldhas a provision to mount EGR valve onto it so as tomatch hole in valve to the hole on inlet manifold.

Note :

Ensure exhaust system and catalytic converter (iffitted) are not blocked and are free from obstruction.

● Blockages in exhaust can create back pressurewhich will result in low top speed, poor pick up,black smoke, carbon build up and high fuelconsumption.

Check and ensure EGR valve & control system isclean and functioning properly.

● Excessive carbon build up / sticky valve.

● Damaged Vacuum lines.

All these can keep ‘EGR’ valve open when not desiredand vice versa. Either way these can seriously affectpower output and also emission levels.

90

4 DLTC ENGINE

ENGINE TESTING

Mount engine on test bed.

Connect gear box to dynamometer flange with suitablecoupling or propeller shaft

Connect oil pressure gauge and temperature gauge.

Connect water hoses to and from radiator. Fill coolant.

Fit radiator cap.

Fill recommended running- in oil.

Mount air cleaner assembly on test bed suitably.Connect hoses from air cleaner outlet to turbocharger,turbocharger to intercooler and intercooler to intakemanifold. Connect oil drain line.

Make suitable linkage for controlling accelerator lever.

Connect exhaust pipe to exhaust manifold.

Connect battery cables to starter motor. Ensure that-ve terminal is earthed. Make suitable connection from+ve terminal of battery to FIP solenoid switch.

Crank engine with accelerator lever in idling position.Run engine for few minutes.

Check and ensure that oil pressure indicated by gaugeis satisfactory.

Slightly raise engine speed and check for oil, fuel,water and air leakages. Rectify if any. Check colourof exhaust gas. Check for any unusual noise fromengine.

Connect engine to dynamometer and run forrunning-in test as per schedule.

Engine running in test schedule

Engine Speed Time Torque(rpm) (minutes) (mkg)

900 5 -

1500 5 3.5

2000 5 5.9

2500 5 7.1

3000 5 8.8

3500 5 9.0

4000 5 9.5

4300 5 10.0

4300 5 13.0

After running-in test, reduce dynamometer load tozero and allow engine to run at idling speed for about5 minutes and then stop it.

Ensure that oil pressure at idling speed & max. speedis as specified.

To prevent entry of dirt/debris into Turbocharger,during testing follow procedure given below :

1. Remove inlet adaptor from turbocharger andpreserve it in a clean place for refitment afterthe test.

2. Fit assy. connector using new & clean filtersieve.

3. Fit assy. oil line inlet. Ensure that this line isinternally clean.

4. Complete engine testing.

5. Remove assy. oil line & assy. connector.

6. Remove used filter sieve & the strainer. Do notreuse old filter sieve & strainer again. Fit a newsieve & strainer and the sealing washer and keepassy. connector ready for next eng.

7. Fit original Adaptor on turbocharger (Refer Sr.No. 1) after ensuring that it is clean.

8. Connect the cleaned standard assy. oil line.

9. Run engine to ensure no oil leakage.

91

4 DLTC ENGINE

SR.NO. COMPLAINT CAUSEREMEDY

1. Engine does not crank Electrical connection Correctloose/came outBattery discharged Recharge/replaceStarter Motor not working Repair/ReplaceMain line switch defective Replace

2. Engine Cranks but No Diesel Fill Dieseldoes not start Fuse for engine stop blown Replace fuse.

Fuel filters choked Replace fuel filters.Solenoid switch on FIP Replace solenoid switchmalfunctionsAir Cleaner choked Clean/Change filter cartrigeEngine seized Repair engineExhaust system choked Clean exhaust systemHydrostatic lock due to Repair enginecylinder head gasket blownValve train failure due to Repair enginetiming belt failure/breakageGlow plugs defective Replace

3. Engine Seizure Low coolant level Arrest leak/RepairCooling fan not working Check belt tensionThermostat failure Replace affected partsRadiator hose leakage -Do-Radiator leakage -Do-Water pump defective/pumpbearing damaged -Do-Fan belt loose/broken Adjust/Replace affected partsFIP timing incorrect/defective -Do-

4. High Engine Oil Oil leakage from :-Consumption a) Crankshaft front oil seal Replace oil seal

b) Crankshaft rear oil seal Replace oil sealc) Sump gasket Tighten sump screws/Replace

gasket, if necessary.d) Oil cooler Tighten fastener/Replace oil

cooler, if necessary.e) Oil filter Tighten filter/Replace if necessaryf) Camshaft front oil seal Replace oil seal.g) Camshaft rear oil seal Replace oil seal.h) Cylinder head cover gasket Replace gasketi) Cylinder head cover warpage Replace cylinder head coverj) Oil seal on valve guide Replace valve guide sealk) Valve guide worn out Replace valve guideExcessive oil filling Fill oil to correct levelExcessive piston ring butt/ Replace piston ringsLateral clearanceExcessive cylinder bore wear Repair the engine(Excessive blow-by)

ENGINE TROUBLE SHOOTING

92

4 DLTC ENGINE

5. Low Engine Oil Pressure Low Pressure warning Replace bulb/indicator switchbulb/indicator switch defectiveLow oil level in sump Top-upOil pump siezed :-a) Siezed Replaceb) Oil pump relief valve stuck Repair/Replace the valve and

in open position affected engine partsMain bearing /con rod bearings Replace affected parts& journals excessively worn outBearing shells peeled off Replace affected partsWrong grade of oil Fill in correct grade of oilDiesel dilution Rectify

6. Engine overheating Defective temperature gauge Replace defective gaugeLess coolant in the system Top upDefective water pump Replace water pumpCooling fan not working Check belt tensionEngine overloaded due to :-a) Brake binding Adjust brakeb) Clutch slippage Replace affected partsDefective FIP/Nozzle Repair/Replace nozzlesWrong FIP timing Correct FIP timingDribbling Injection Nozzles Repair/Replace nozzles.

7. Abnormal Noise Noise from bearing block Repair/Replace bearing blockfrom engine Noise from Alternator Repair/Replace

Noise from power steering pump Repair/ReplaceNoise due to improper tappet setting Adjust tappet clearanceTiming belt/Power steering belt loose Adjust tension/Replace beltWater pump bearing failure Replace bearings/Water pumpCon Rod bush worn out Replace Con Rod bushesBig end/Main bearings & Replace affected partsjournals of crankshaft worn outPiston Ring broken Replace affected partsCrankshaft broken Replace affected partsSilencer choked Clean silencerAir Cleaner Element choked Clean/Change elementFuel Filters choked Replace fuel filtersMalfunctioning of Solenoid Replace solenoid switchswitch on FIPMalfunctioning of FIP Recalibrate/Repair the FIPDefective Injectors Repair/Replace Injectors


93

4 DLTC ENGINE

8. Low compression a) Leakage of compression Repair /Replace valves and valve seatpressure from engine valves inserts

b) Cylinder Head gasket blown Replace gasketbetween two cylinders

c) Leakage of compression Replace piston ringspast piston ring buttclearance (blow by)

d) Leakage of compression Overhaul the enginedue to excessive cylinderbore/ring wear (indicatedby excessive blow by).


94

4 DLTC ENGINENOTES

1

CLUTCH

CLUTCH

3

CLUTCH

Clutch is the mechanism interposed between engine

and the gear box which enables engine power as well

as torque of the engine to be transmitted at WILL to

the gear box through friction drive. When clutch pedal

is depressed the clutch is disengaged therefore motion

and power flow from engine to gear box and hence to

road wheels is disconnected.

INTRODUCTION :

5

CLUTCH

CONTENTS

SR.NO. DESCRIPTION PAGE NO.

1. Mounting arrangement of clutch parts 7

2. Preliminary inspection 8

3. Clutch disc & pressure plate cross-sectional view 9

4. Specifications 10

5. Removal of clutch from vehicle 10

6. Inspection of components 11

7. Installation of clutch on vehicle 11

8. Exploded view of clutch & brake control parts 12

9. Removal of clutch actuation mechanism 13

10. Clutch master cylinder - BI TVS 14

11. Clutch master cylinder - KXB 16

12. Clutch slave cylinder - BI TVS 18

13. Clutch slave cylinder - KBX 18

14. Installation of clutch actuation mechanism 20

15. Bleeding the clutch system 21

16. Clutch pedal linkage adjustment 21

7

CL

UT

CH

Fig.1 - Clutch release fork arrangement

CLUTCHDISC

CLUTCHMOUNTING BOLTS

THIS POCKETOF RELEASESLEEVE TO BEFILLED WITHGREASE 3%MOS2

LUBRICATE THESURFACE WITH

GREASE 3% MOS2

CLUTCHHOUSING

CLUTCHRELEASEBEARING

CLUTCHCOVER

Fig.2 - Clutch parts and the mounting arrangement

LUBRICATE FORKBEARING SURFACE WITH

GREASE 3% MOS2

WEARPOSITION

ENGAGEDPOSITION

DISENGAGEDPOSITION

ASSY. CLUTCHRELEASE FORK

CLUTCHHOUSING

LUBRICATE THEFORK, SPRING

PLATE & BALL PINBEARING WITH

GREASE 3% MOS2

BALL PIN

BACKCOVER

LOCKINGWIRE

COVERINSPECTIONWINDOW

MO

UN

TIN

G A

RR

AN

GM

EN

T O

F C

LU

TC

H PA

RT

S

8

CLUTCH

C. OPERATING CONDITIONS

Vehicles operating on shorter runs, cityoperations, off highway and operations in hillyterrains are obviously subjected to more numberof clutch operations and thereby higher clutchwear.

3. PRELIMINARY INSPECTION OF CLUTCH

Clutch needs replacement mainly on account ofclutch slippage or imperfect engagement anddisengagement. This may be due to worn out /damaged clutch parts. It is desirable to carry outfollowing preliminary checks before removal ofclutch.

A. CLUTCH SLIPPAGE TEST

Clutch slippage can be confirmed by any of thefollowing methods given below :

a) Drive vehicle in 1st or 2nd gear atmaximum speed corresponding to that gear.With accelerator pedal fully pressed, applybrake gradually with left foot. If the enginestalls, it means that clutch does not slip.

b) Drive loaded vehicle in 3rd gear on levelground and let vehicle speed drop down toapproximately 15 kmph / 9 mph. Now pressaccelerator pedal fully. With slipping clutch,vehicle speed will not pick up and also clutchburning smell will be noticed. If this does notoccur and vehicle picks up speed, it indicatesthat clutch does not slip.

B. CLUTCH ENGAGEMENT ANDDISENGAGEMENT TEST

During the above test, when vehicle is in motion,depress clutch pedal fully without changingaccelerator pedal position. If engine speedincreases immediately, perfect clutchdisengagement is indicated. Further, release theclutch pedal suddenly. If vehicle moves forwardwith a little jerk, perfect clutch engagement isindicated.

Caution

This test should be carried out with utmost carebecause sudden release of clutch might causeheavy jerk and damage to clutch lining.

1. CONSTRUCTION

Single disc dry friction clutch with 228 mm dia.clutch disc is used.

Pressure plate assembly is diaphragm spring type.Clutch release bearing is self centering type andassembled with release fork and guided on driveshaft cover tube of gear box. Clutch is actuatedby a hydraulic master cylinder and slave cylinder.Routine clutch adjustments are not necessarydue to diaphragm clutch & hydraulic actuationsystem.

2. FACTORS AFFECTING CLUTCH WEAR

Clutch is designed to give maximum life undermost severe conditions when handled carefully.However, while in operation, clutch lining issubjected to wear. Apart from this, the extent ofwear also depends on following.

A. PROPER MAINTENANCE

Maintenance of clutch includes adjustment ofpedal stopper bolt, checking oil level and bleedingthe system for defect free operation of clutchactuation mechanism and periodic lubrication.

B. DRIVING

Following driving conditions will affectperformance of clutch.

i. Clutch riding

Using clutch pedal as a foot rest by keeping footconstantly on pedal while driving will cause partialclutch disengagement. It will result in slipping ofthe clutch disc and premature failure of the clutch.

ii. Permitting the clutch to slip too long

Half clutch driving and thereby permitting theclutch purposely to slip too long will have thesame result as above.

iii. Permitting the clutch to jerk

Sudden clutch engagement at higher enginespeed specially while moving out stranded vehiclewill cause severe instantaneous clutch loading,resulting in clutch slippage and burning of thelining. Starting the vehicle in first gear under suchconditions will avoid such problem. Always startvehicle in first gear.

9

CLUTCH

Fig. 3 - Cutch disc

Fig.4 - Clutch pressure plate assembly

DIAPHRAGM SPRING

DIAPHRAGMRIVET

PIVOT RING

PRESSURE PLATE

COVER

RIVET RIVETDAMPERSPRING

HUB

RIVET CLUTCHLINING

➝❁

➝❁ A

PRESSUREPLATESIDE

FLYWHEEL

SIDE

RELEASEBEARING

STRAPERIVET

STRAPRIVET

Parts

STRAP

10

CLUTCH

4. SPECIFICATIONS

A. CLUTCH DISC (Fig.3)

Outside diameter 228 +1 mm.

Inside diameter 150 + 1.5 mm._ 1.0

Thickness of clutch disc 9.3 ± 0.3 mm.with new lining under570 kg load ‘A’

Maximum permissible 0.5 mm.out of perpendicularityof each lining surface ofclutch disc w.r.t. splineaxis at 223 mm diameter

Maximum permissible 25 gm-cm.imbalance of clutch disc

Cushioning of clutch disc 0.9/1.2 mm

Spline size of clutch disc A10 x 23 x 29 (DIN 5464)

Total friction area 463 sq.cm.(both sides)

B. CLUTCH PRESSURE PLATE ASSEMBLY (Fig.4)

Height of pressure plate 34.5 mm.housing ‘A’ max.

Height of diaphragm 28.2 ± 1 mm.tip from cover mountingsurface ‘B’

Max. permissible imbalance 20 gm-cm.of pressure plate assembly

Max. permissible face run 0.5 mm.out of release bearingcontact surface of diaphragm

Clamp load on clutch disc 570 to 660 kg.

Diaphragm release load Max. 210 kg.(with gauge plate)

Tip travel, 'C' 8 +1 mm.

Max tip travel after use of disk, 'D' max.8.5 mm.

Pressure plate lift for min. 1.8 mm.release travel 8+1 mm

C. CLUTCH ACTUATION HYDRAULIC SYSTEM

Clutch master cylinder 19.05 mm.diameter

Clutch master cylinder 34.5 mm.stroke

Slave cylinder diameter 23.81 mm.

Slave cylinder stroke 52.0 mm.

5. REMOVAL OF CLUTCH FROM VEHICLE

● Place chokes on wheels to prevent movementof vehicle.

● Disconnect battery and electrical connections ofstarter motor.

● Loosen mounting bolts and remove starter motor.

● Unlock and remove U/J cross mounting stripscrews at gear box end. Disconnect propeller shaftfrom gear box and suspend it sideways suitably.

● Loosen and remove clutch slave cylindermounting nuts and tie it suitably.

● Pull out reverse indicator switch cable connector.

● Disconnect speedo cable

● Disconnect and remove gear box along with clutchhousing from engine

● Remove clutch release bearing with sleeve.

● Pull out clutch release fork from spring clip.

● As a safety measure, support clutch pressureplate and clutch disc with mandrel 2654 5890 2501. Unscrew six mounting bolts evenly (alternatelyand crosswise) in small steps.

● Remove pressure plate assembly and clutch discalong with mandrel.

11

CLUTCH

6. INSPECTION OF COMPONENTS

i. Check clutch disc hub splines for damage andwear. Clutch disc should slide easily on gear boxdrive shaft but should not have excessive playand wobble.

ii. Check torsion damper mechanism springs fordistortion, damage etc. For this purpose, holddrive shaft in vice. Insert clutch disc and slide itas far back as possible. Rotate disc by hand.Rattling noise and excessive play indicatesdamaged torsional damping mechanism and suchdisc must be replaced.

iii. Check disc facing for wear, cracks, contactpattern, burning marks and oil contamination.Facings with any of the above defects or wornout beyond permissible limits must be replaced.

Note

It is recommended to replace a NEW genuineclutch disc if any defects are noticed. We do notrecommend clutch lining change.

We do not recommend overhauling of clutchpressure plate assembly. It should be checked forserviceability and should conform to specifications.

Caution

Prior to installing a new clutch disc, check forface run-out and straighten, if required.

Ensure that clutch facing material is notcontaminated with oil or grease as this will resultin clutch slippage.

7. INSTALLATION OF CLUTCH ON VEHICLE

Proceed in reverse order of removal of clutch.However, following care must be taken duringinstallation :

● Clean friction face of flywheel and check forcracks, scoring, burn marks or unevenness. Ifnecessary, machine flywheel friction face just toclear the defect.

● Check spigot bearing in crankshaft for freerotation. Replace sticky/damaged bearing. Fit newbearing after filling with bearing grease and pressin the retaining cover.

Lightly apply grease (3% MoS2) on the discsplines. Install disc and pressure plate assembly(Gear box side is marked on the disc). Pressaligning arbor through pressure plate assemblyand clutch disc and centralize clutch disc onflywheel by locating front end of the arbor in crankshaft spigot bearing.

● Locate the cover assembly in the spigot diameterof the flywheel and align its mounting holes withtapped holes in flywheel. Screw in clutchmounting screws with spring washers. Aligningarbor still in position, tighten mounting screwsevenly and equally (alternately and cross wise)in small steps. Tighten these screws in the samesequence to 3 mkg torque.

Note

Do not mix clutch mounting bolts with otherfasteners. Do not use longer or shorter screws.Longer screws may not tighten the clutch at all.Shorter screws will not provide enough threadsto achieve desired tightening.

● While tightening clutch mounting screws checkaligning arbor for continuous free sliding to ensureconcentric installation of clutch disc which willavoid trouble when installing gear box.

● Fill pocket of release bearing sleeve with (3%MoS2) grease.

● Lubricate the fork, spring plate and ball pin bearingarea with (3% MoS2) grease.

● Lubricate slave cylinder fork bearing surface with(3% MoS2) grease.

12

CLUTCH

Fig.5

1. ASSY CNTRL MTG BRKT WITH BRAKE &CLUTCH PEDALS

2. ASSY CONTROL MTG BRACKET3. ASSY. CLUTCH PEDAL LEVER4. ASSY BRAKE PEDAL LEVER5. SPACER6. RUBBER COVER (BRAKE & CLUTCH

PEDAL)7. PIVOT BUSH8. PIN (FOR PEDAL MTG.)9. STAY ROD (FOR CLUTCH ASSISTANCE)10. COMPRESSION SPRING (FOR CLUTCH

ASSISTANCE)11. PIVOT PIN12. RETURN SPRING (PEDAL LEVER)13. ASSY. STOPPER BOLT

CLUTCH & BRAKE CONTROL

14. RUBBER CAP (FOR PEDAL LEVERSTOPPER)

15. STOPPER BOLT16. STOP LIGHT SWITCH17. ASSY. CLUTCH MASTER CYLINDER18. ASSY. PIN19. CLEVIS PIN20. BUSH21. RUBBER SPACER22. CLUTCH SLAVE CYLINDER23. RUBBER SEALING24. ADJUSTING ECCENTRIC PIN25. ASSY. HOSE26. ASSY. CLUTCH PIPE27. CLAMPING PLATE

S. NO. DESCRIPTION S. NO. DESCRIPTION

13

CLUTCH

Fig. 6 - Clutch Actuation Mechamism for vehicle with 4DL TC engine

1. Clutch master cylinder

2. Clutch pedal stopper

3. Split pin

4. Clevis pin

5. Clutch pedal

* If required adjust theMaster Cylinder dimension A = 126to ensure diamension 225+10

Adjust clutch pedal stopper toget pedal travel of 160-5

A

160-5

7. CLUTCH ACTUATION MECHANISM

Removal

1. Connect bleeding tube to bleeding screw on slavecylinder.

2. Loosen bleeding screw on slave cylinder by 1/ 2to 3/4 turn. Operate clutch pedal number of timesand pump out fluid into a clean container.

3. Remove bleeding tube.

4. Disconnect pipe connection from master cylinder.

5. Disconnect pipe connection from slave cylinder.

6. Remove split pin and clevis pin, locking mastercylinder push rod fork end with clutch pedal.

7. Unscrew and remove master cylinder mountingscrews. Pull out master cylinder.

8. Remove filling container cap and unscrewcontainer mounting banjo bolt. Remove gasket.

9. Unscrew and remove slave eylinder mountingscrews and pull out slave cylinder.

14

CLUTCH

Fig. 7 - Clutch Master Cylinder Sectional View - Brakes India Make

1. FILLING CONTAINER2. BANJO BOLT & GASKET3. VALVE SEAL4. SPRING WASHER5. VALVE SPACER6. SPRING7. VALVE STEM8. SPRING RETAINER9. GLAND SEAL10. BODY MASTER CYLINDER11. PLUNGER12. RETAINING WASHER13. CIRCLIP14. PUSH ROD15. DUST COVER16. LOCKNUT17. FORK

8. CLUTCH MASTER CYLINDER - Brakes IndiaMake

DISMANTLING OF MASTER CYLINDER (Fig. 7)

● Pull back dust cover. (15)

● Remove circlip retaining push rod (14)

● Remove push rod with retaining washer (12)

● Remove plunger (11) and valve assembly frombody by lightly tapping the body on wooden block.

● Using a screw driver, lift the leaf of spring retainer(8). Remove spring assembly from plunger.

● Compress spring (6) to free valve stem (7) fromeccentrically positioned hole in the end face ofspring retainer. This will separate spring retainerfrom valve stem.

● Remove spring, valve spacer (5) and springwasher (4) from valve stem.

● Carefully remove valve seal (3) from valve stem.

● Carefully remove gland seal (9) from plunger.

15

CLUTCH

INSPECTION AND ASSEMBLY OF MASTERCYLINDER (Fig. 7)

● Examine bore of body. If it is not scored, ridgedor corroded, do not replace. If there is damage inthe bore, the cylinder assembly should bereplaced. Even otherwise if the clearance betweenplunger and the bore exceeds 0.13 mm, theassembly should be replaced.

● Examine plunger for rust, burrs and ridges,Replace if necessary.

● Fit new gland seal on plunger such that it fitssquarely in plunger groove.

● Fit new valve seal on valve stem with the smallestdiameter leading.

● Assemble spring washer on valve stem such thatit bends away from valve shoulder.

● Now assemble valve spacer on valve stem. Holdthe spacer between fingers such that the valvestem hangs down vertically. Pull the stemdownwards as far as possible. Release the stem.Observe whether the valve stem has movedfreely upwards. If movement is not free replacevalve spacer.

● Install spring over valve stem behind valvespacer, followed by spring retainer. Compressspring and locate valve stem end in key hole slotof spring retainer.

● Fit spring assembly on plunger assembly and lockthe leaf of spring retainer by pressing it with nosepliers.

● Lubricate bore of body with brake fluid and dipplunger valve assembly in it. Insert the assemblyinto bore with valve end leading.

● Check condition of dust cover. If necessaryreplace.

● If disturbed, adjust push rod length with fork tospecified value.

● Place push rod with retaining washer on plungerand fit circlip for retaining push rod in the bodygroove.

● Fit dust cover on body.

16

CLUTCH

Fig. 8 - Clutch Master Cylinder - KBX make Exploded view

1. Master Cylinder housing2. Master Cylinder housing3. Piston assembly4. Fork assembly5. Container lid6. Adopter for clutch fluid container7. Piston stop ring8. Screw9. Clutch fluid container10. Filter

11. Rubber boot12. Boot ring13. Seal inlet valve14. Rod inlet valve15. Cup washer16. Case inlet valve17. Return spring18. Spring container19. Piston seal20. Shackle

CLUTCH MASTER CYLINDER - KBX

Hydraulic Clutch Actuation used in modern vehiclesminimizes the driver’s effort while clutch application.This system consists of Clutch Master Cylinder &Clutch Slave Cylinder. When the clutch pedal isdepressed the hydraulic pressure is generated in theclutch master cylinder & the pressure is transmittedto slave cylinder via pipe & this pressure is used fordeclutching.

1. Operation –

Clutch Master Cylinder (CMC) of this particular typeis of center valve type & consists of a pistonassembly , Seal , return spring & push rod assembly& clutch fluid reservoir. When the clutch pedal isdepressed the push rod pushes the piston in the boreof clutch cylinder. This movement of piston closesthe inlet port by actuating the center valve & thefluid in front of the seal is then pressurized & thehydraulic pressure thus created actuates the slavecylinder which in turn declutches the transmission.

2. Overhauling of CMC Assembly (KBX) –

2.1 Dismantling of CMC Assembly (KBX) –

1. Hold the CMC assembly in a soft jaw vice.

2. Fold the boot & after pushing the push rodgently in the bore, remove the piston stopring with the help of a screw driver.

3. Remove the piston assembly by tapping theCMC assembly gently on a wooden block.

4. Dismantle the piston assembly by slightlybending the locking lug of the spring retainer(18).

5. Remove the rod, inlet valve (14) bycompressing the spring(17). Removethe case inlet valve (16) ,inlet valve seal (13)& cup washer (15) & also the piston seal(19).

17

CLUTCH

6. Hold the shackle (20) of pushrodsubassembly in a soft jaw vice.. Unscrewthe lock nut & remove push rod & boot (11).

7. Clean all the dismantled internal parts withthe fresh brake fluid.

2.2 Inspection of Parts –

Inspect the bore & piston of the CMC. If it is notscored , ridged or pitted and smooth, the CMC canbe rebuilt with the genuine repair kit. If in case ofslightest doubt on the bore condition, like deep grovesor score marks in the bore then a new cylinderassembly should be replaced.

Note :Do not polish the piston od / cylinder bore with anyabrasive material which may damage the surface.

Destroy all old parts to prevent misuse.

2.3 Assembly of CMC Assembly (KBX) –

1. Lubricate all the internals like piston & newrubber seals with fresh specified brake fluid.

2. With the help of mandrel assemble the sealson the piston properly.

3. Assemble seal - inlet valve (13) on rod - inletvalve (14). Insert cup washer(15) & case -inlet valve (16) & return spring (17) with springretainer (18) on rod - inlet valve (14) .Insertthis whole assembly on piston & lock thespring retainer lug on the piston stem.

4. After lubricating the CMC bore with freshbrake fluid insert the piston gently into thebore.

NOTE :

Keep the piston straight while inserting in thebore. Any tilt may jam it half way through intothe bore.

5. Assemble piston stop plate & rubber boot(11) & boot ring (12) on push rod & assemblelock nut & shackle (20).

6. By pressing the pushrod & inturn the piston,gently in the bore fit the piston stop ring (7).

7. Hold the CMC assembly in vertical directionby keeping the pushrod pointing downwards.Check the distance from mounting flange toshackle pin hole center. Adjust this distanceto 126 + (-) 0.5 mm by rotating the pushrod& lock the shackle by tightening the lock nutto 1.3 to 1.6 Kg- m torque.

8. Install the CMC Assembly on the vehiclereferring the vehicle manufacturer’sinstructions.

9. Bleed the hydraulic circuit to remove air fromthe system.

10. Ensure that the filter (10) is clean beforerefitting the cap (5). Ensure the breathing holeprovided in the cap (5) is not blocked by dustor dirt.

NOTE :

Clutch master cylinder assemblies make BI TVS& KBX makes are used in selection. Repair kitsfor for both makes are different.

Please ensure usages of correct make / size ofrepair kit during overhaul.

18

CLUTCH

Fig. 9 - Slave Cylinder - Brakes India Make

1

2

3

5

6 7 84

1. PUSH ROD2. WASHER3. DUST COVER4. CIRCLIP5. PLUNGER

6. SEAL7. SPRING8. BODY9. BLEED SCREW10. PISTON SEAL

9

68.7 mm.

10

DISMANTLING OF SLAVE CYLINDER (Fig. 9)

● Remove circlip (4) and washer (2).

● Remove rubber boot (3).

● Remove plunger (5) with gland seals and plungerspring (7) from body by lightly tapping it onwooden block.

● Remove gland seals (6 & 10) from plunger.

INSPECTION AND ASSEMBLY OF SLAVECYLINDER (Fig. 9)

● Examine bore of body. If it is not score, ridged orcorroded do not replace. If there is doubt aboutcondition of bore, then it should be replaced withnew slave cylinder assembly. Even otherwise ifthe clearance between the plunger & bore exceeds0.13 mm. the assembly should be replaced.

● Examine plunger for rust, burrs, and ridges,Replace if necessary.

● Fit new gland seals on plunger such that it fitssquarely in plunger groove.

● Fit small end diameter of spring to plunger.

● Lubricate bore of body with brake fluid and dipplunger assembly in it. Insert plunger assemblyinto bore with bigger end diameter of springleading.

● Fit rubber boot & washer over push rod and placeit over plunger as shown. Fit circlip.

● Ensure the push rod length from the slave cylindermounting face is as shown in sketch.

9. SLAVE CYLINDER - Brakes India Make

19

CLUTCH

Fig. 10 - Slave Cylinder - KBX make Exploded view

1. Slave Cylinder assembly2. Slave Cylinder assembly3. Circlip4. Dust cap5. Push rod kit6. Piston kit7. Washer8. 'O' ring9. Spring10. Bleed screw11. Primary seal12. Secondary seal13. Clamp ring14. Rubber boot15. Clamp ring

SLAVE CYLINDER - KBX

Hydraulically Actuated Clutch used in modernvehicles optimize the driver’s effort while clutchapplication. The actuation system consists ofClutch Cylinder (CMC ) & Clutch Slave Cylinder(CSC ).

1. Construction –

The hydraulic clutch system consists of ClutchMaster Cylinder & Clutch slave cylinder.

The hydraulic pressure developed in Clutch MasterCylinder is transmitted to the Clutch SlaveCylinder through a hydraulic line where thehydraulic pressure actuates the clutch slavecylinder push rod which operates the clutchrelease mechanism. The clutch slave cylinder ismounted on clutch housing.

The slave cylinder consists of a piston , pistonreturn spring, seals & boot .

Note :

Length of slave cylinder push rod for Telcoline &other tata models may vary. Please ensure to useappropriate slave cylinder push rod during repairs.

2. Overhauling of CSC Assembly –

2.1 Removal of CSC from vehicle –

1. Remove the bleed screw cap from the bleederprovided on CSC assembly.

2. Attach a plastic tube to the bleed screw & putother end of the tube into acontainer.

3. Unscrew the bleed screw for ½ or ¾ turn.

4. Push the clutch pedal to pump the fluid outfrom the CSC.

5. Dismantle the CSC assembly from the vehiclereferr ing to the vehicle manufacturer’sinstructions.

2.2 Servicing of CSC assembly –

1. Hold the clutch slave cylinder in a soft jawvice.

2. Unscrew the bleed screw.

3. Remove the boot.

4. Push the piston with a hylem rod or bluntedge screw driver & remove the circlip.

20

CLUTCH

5. Remove the piston & piston return spring bytapping the CSC assembly gently on

a wooden block.

6. Remove the seals by cutting it from thepiston.

7. Clean all the dismantled parts with the freshbrake fluid.

NOTE :

Never use any mineral oil base fluids likekerosene,diesel thinner, petrol etc,. For cleaning ofremoved parts.

2.3 Inspection of Parts —

Inspect the bore & piston of the CSC. If it is notscored , ridged or pitted and smooth, the CSCcan be rebuilt with the genuine KBX spare partskit. If in case of slightest doubt on the borecondition, like deep groves or score marks in thebore then a new cylinder assembly should bereplaced.

Note :

Do not polish the piston/ cylinder bore with anyabrasive material which may damage the surface.

Destroy all old parts to prevent misuse.

2.4 Assembly of the Clutch Slave Cylinder –

1. Lubricate all the internals like piston & newrubber seals with fresh specified brake fluid.

2. With the help of mandrel assemble the sealson the piston properly.

3. Insert the piston return spring on the pistonstem.

4. Insert the piston assembly with return springinto the bore with the spring end leading.

5. Push the piston slightly into the bore & applyrubber grease provided in the repair kit onpiston spherical end where the push rod ofCSC assembly is fitted.

6. Assemble pushrod , boot ring, boot & bygently pushing the boot into the bore,assemble the piston stop plate & fit the circlip.

7. Install the CSC Assembly on the vehiclereferring the vehicle manufacturer’sinstructions.

8. Bleed the system to remove air from thesystem

NOTE :

Clutch slave cylinder assemblies make BI TVS& KBX makes are used in selection. Repair kitsfor for both makes are different.

Please ensure usages of correct make / size ofrepair kit during overhaul.

10. INSTALLATION OF CLUTCH ACTUATIONMECHANISM

● Install clutch pedal bush if removed earlier, usingsuitable drift.

● Locate clutch pedal in the mounting bracketproperly and insert hex bolt. Smear oil on insidesurface of clutch pedal bush while assembling.

● Fit and tighten two hex nuts on clutch pedalmounting bolt. Ensure free movement of leverafter tightening.

● Locate clutch master cylinder fork properly. Pushthe eye end and fit it on the mounting pin at clutchpedal carefully. Install washer and split pin andbend the split pin.

● Mount slave cylinder on clutch housing. Makesure that push rod end is properly located atclutch fork seat.

● Ensure that bleeding screw of slave cylinder isat top. Tighten slave cylinder mounting nuts.

● Install master cylinder on fire wall and tighten itsmounting screws.

● Connect pipe connection to slave cylinder.

● Connect pipe connection to master cylinderproperly.

21

CLUTCH

Fig. 10- Bleeding the clutch system

11. BLEEDING THE CLUTCH SYSTEM

Procedure for bleeding the system given below :

● Top up clutch fluid container.

● Ensure that fluid level in clutch fluid container isup to ‘Max’ level and not above it. Add clutchfluid to maintain level while bleeding.

● Remove dust cap from slave cylinder bleed screwand clean the screw thoroughly. Attach bleedingtube to bleed screw and place other end of tubein a clean glass jar containing sufficient clutchfluid to submerge tube end.

● Pump clutch pedal twice or thrice slowlythroughout its stroke and by holding clutch pedalin depressed condition, loosen bleed screw oncylinder.

● Retighten bleed screw on slave cylinder andrepeat the above operation until air bubbles ceaseto appear at the end of tube in glass jar, allowingonly fluid to flow.

● After completing bleeding operation, ensure thatbleed screw on slave cylinder is fully tightened.Replace dust cap on the bleed screw.

Note

During bleeding process keep a watch on fluidlevel in container and top up if the level falls belowthe indicated mark.

12. CLUTCH PEDAL LINKAGE ADJUSTMENT

Clutch pedal free play is due to clearancebetween plunger and push rod of master cylinder.This cannot be adjusted. It is built in designfeature.

● Adjust the dimension between push rod fork holecentre to master cylinder flange face (A=126 mm)Refer fig. 6

● Assemble master cylinder on firewall.

● Assemble clutch pedal and master cylinder pushrod fork with pin, collar bush, washer and splitpin. Smear oil while assembling pivot pin of clutchlever.

● Screw in pedal stopper bolt completely. Presspedal fully till the pedal bottoms on the floor. Nowscrew out the pedal stopper bolt till it touchesthe pedal lever, release pedal. (Fig.5)

● Set the clutch pedal travel to 160-5 mm byadjusting clutch pedal stopper.

● Screw out the bolt further by one turn. Tightenthe locknut.

● Press the clutch pedal 3-4 times and check forproper functioning.

1

GEAR BOX G-76

GEAR BOX G-76

3

GEAR BOX G-76

The G-76 gear box has an input torque capacity of

20.5 kgm. All gears, five forward and one reverse are

synchromesh. The fifth gear is an overdrive for better

fuel efficiency at higher speeds.

In order to improve the gear shifting user friendly

pattern is introduced. Aluminium alloy die cast shifting

system is used to keep the weight of the gear box

low, & its function is improved by multi rail shifting

system.

INTRODUCTION :

5

GEAR BOX G-76

CONTENTS

SR. NO. DESCRIPTION PAGE NO.

1. Construction

i. Sectional View 07

ii. Exploded Illustrated View 09

iii. List of Parts 10


3. Special Tools List 14

4. Removal of G-76 gear box from Vehicle 15

5. Dismantling of Gear Box 16

6. Disassembly

i. Drive Shaft 23

ii. Main Shaft 23

iii Counter Shaft 26

iv. Gear Box Housing Rear Half 27

v. Gear Case Cover Front 28

vi. Gear Case Cover Rear 28

7. Assembly of Sub-Assemblies

i. General Instructions 29

ii. Identification Parameters 30

iii. Engaging Gears 32

iv. Main Shaft 33

v. Counter Shaft 36

vi. Drive Shaft 36

8. Measurement of Control Dimensions 37

9. Sub- Assembly

i. Gear Box Housing Cover Front 43

ii. Gear Box Housing Cover Rear 43iii. Shifter and Selector Shafts 44

iv. Gear Box Housing Rear Half 45

10. Assembly of Gear Box 46

11. Assembly of Gear Shift Linkage 51

12. Installation of Gear Box on Vehicle 52

13. Troubleshooting 53

14. G-76 Improvements -Supplement 55

GEAR BOX G-76

7

GEAR BOX G-76

8

GEAR BOX G-76

9

10

GEAR BOX G-76

ILLU.NO. DESCRIPTION

1. DRIVE SHAFT

2. BEARING TUBE(DRIVE SHAFT cover)

3. OIL SEAL (DRIVE SHAFT)

4. COMPRESSION SPRING(DRIVE SHAFT)

5. SPACER THRUST BEARING

6. THRUST BEARING (MAIN SHAFT)

7. ROLLER CAGE (DRIVE SHAFT)

8. GEAR CASE COVER - Front

9. HEX SCREW -M6X12

10/10a SHIM (MAIN SHAFT)

11/11a TAPER ROLLER BEARINGDRIVE SHAFT

12. DOWEL PIN

13. BREATHER

14. SEALING CAP

15. SNAP RING

16. SPACER - Engaging gear 3rd

17/17a SYNCHRO CONE 3rd/4th

18. SHIFTER SLEEVE 3rd & 4th

19/19a/19b SPRING

20/20a/20b Carriers

21a/21b/21c BALL 5 dia

22. ENGAGING GEAR 3rd/4th

23. 3rd SPEED GEAR

24/24a NEEDLE CAGE 2nd/3rd

25. BUSH 3rd

26. BALL 3 dia

27. SPACER 2nd/3rd

28. LINEAR BEARING

29. 2nd SPEED GEAR

30. SYNCHRO CONE 2nd & 5th

31/31a SNAP RING

List of Parts Illustrated in fig. A, B, C.


32/32a ENGAGING GEAR 1st/2nd & Rev/5th

33. SHIFTER SLEEVE 1st/2nd

34/34a SYNCHRO CONE 1st & Rev.

35. 1st SPEED GEAR

36/36a NEEDLE CAGE 1st & Rev.

37. REVERSE SPEED GEAR

38. SHIFTER SLEEVE Rev./5th

39. NEEDLE CAGE (5th)

40. SPACER (5th/Tapper Roller Bearing)

41. 5th GEAR

42. SPEEDO DRIVE GEAR

43. OIL SEAL - Main Shaft)

44/44a COUPLING FLANGE / SPICER YOKE

45. COLLARED HEX NUT

46. MAIN SHAFT

47. PLUG SPEEDO METER DRIVE

48. SPEEDO METER DRIVE GEAR

49. SPEEDO SHAFT

50. THREADED PLUG - Speedo shaft

51. OIL SEAL - Speedo shaft

52. HEX. SCREW M8X20

53. SPR. WASHER B8

54/54a HEX SCREW M8x40

55/55a BRIGHT WASHER 8.4

56/56a SPR. WASHER B8

65. HEX. NUT M8

66. BRIGHT WASHER 8.4

67. SPR. WASHER B8

68. GEAR CASE COVER -Rear

69. COUNTER SHAFT

70/70a SHIMS (COUNTER SHAFT)

71/71a TAPER ROLLER BEARING(COUNTER SHAFT)

72. SPACER COUNTER SHAFT Rear Cover

11

GEAR BOX G-76


73. O.D. GEAR (COUNTER SHAFT)

74. DOUBLE GEAR(COUNTER SHAFT)

75. EXTERNAL CIRCLIP 38x1.75

76. SPACER (COUNTER SHAFT)

77. G.B. HOUSING - Front half

78. MAGNETIC DRAIN PLUG

79. GASKET - Front half

80. G.B. HOUSING - Rear half

81. SCREW PLUG - Oil filling

82. R.I. SHAFT

83/83a SNAP RING Reverse Idler Gear

84. ROLLER RING Reverse Idler Gear

85. REVERSE IDLER GEAR

86. RETAINER PLATE

87. CAP Shifter Shaft

88. CORE PLUG 25 dia.

89. DETENT

90. DETENT SPRING -Shifter Shaft Central

91. PLUG

92. SPIRAL PIN 6x28

93. SELECTOR & SHIFTER FINGER

94. SHIFTER SHAFT - Rev.

95. SWING LEVER

96. PIN Swing Lever

97. CIRCLIP

98. BEARING BLOCK - Swing Lever

99. HEX. FIT. BOLT

100. SPR. WASHER B10


102. HEX SCREW M6x18

103. BRIGHT WASHER A6.4

104. SPR. WASHER B6

105. HEX. NUT M6


106. ROLLER Detent plate

107. ROLLER Selector lever

108. ASSY. SELECTOR LEVER

109. PIN SELECTOR LEVER

110. TUBULAR SPACER

111. TORSION SPRING

112. ASSY SELECTOR& SHIFTER SHAFT

113. ROLLER - Selector & Shifter shaft

114. PIN

115. SPACER - Selector & shifter shaft

116. OIL SEAL - Selector & shifter shaft

117. SHIFTER SHAFT REV/5th

118. SHIFTER SHAFT 3rd/4th

119. SHIFTER SHAFT 1st/2nd

120. SHIFTER FORK REV/5th

121. SHIFTER FORK 1st/2nd

122. SHIFTER DOG 1st/2nd

123. SHIFTER FORK 3rd/4th

124. SPIRAL PIN 6 x 24

125. PLUG MC 10x1

126. SOCKET HD. CAP SCREW M8x16

127. SPR. WASHER B8

128. LOCATING PIECE Rev. shifter shaft

129. REVERSE LIGHT SWITCH

130. HEX SCREW M6x18

131. SPR. WASHER

132. PRESSURE PLATE Rev. Speed

133. PRESSURE PLATE 5th. Gear

134. SPRING Detent plate 5th gear

135. THREADED PLUG5th. Pressure plate

135a. THREADED PLUGRev. Pressure plate

136. SPRING Plunger

137. PLUNGERRev. Gear detent

12

GEAR BOX G-76


138/138a BALL 8 dia

139. GASKET Detent cover

140. DETENT COVER

141. DETENT SPRINGRev/5th Shifter shaft

142. DETENT SPRING 1st/2nd & 3rd/4thShifter shaft

143. SEALING CUP

144. HEX. SCREW M8x18

145. SPRING WASHER B6

146. PIN 12.8 LENGTH

147. HEX. NUT M8


149. SPRING WASHER B8

150. EXTENSION ARM BRACKET

151. EXTENSION ARM

152. GEAR SHIFT LEVER KNOB

153. HEX LOCK NUT or SPACER forTatamobile

154. RUBBER BELLOW

155. GEAR SHIFT LEVER

156. BASE PLATE

157. CLAMPING PLATE

158. SL. CH. SCREW M8x16


160. RUBBER SEALING Ext. arm to tunnel

161. O RING 31.5 x 2.65

162. BUSH - Ball seat gear shift lever

163. RUBBER BELLOW

164. EXTENSION BOX SUPPORTESTATE

165. EXTENSION BOX SUPPORTSIERRA

165a. ASSY. BRACKET WITH BUSH (EXT.ARM SUPPORT) SAFARI


167. NYLOCK NUT M10x1

168. EXTENSION ARM SUPPORTBRACKET

169. SHIFTING YOKE sel. & shifter shaft

170. SPRING CLIP

171. CYLINDRICAL PIN

172. SHIFTING LINK

173. SPRING WASHER A10

174. WASHER

175/175A EXTERNAL CIRCLIP E7x0.9

176. BUSH Shifting yoke

177. BUSH G B lever

178. PIN Extension arm bkt.

179. BUSH Extension arm.

4 x 4180. GASKET (Between Rear cover

& Adaptor Housing)

181. ADAPTER HOUSING

182. SPACER (OIL SEAL)

183. EXTERNAL CIRCLIP 30 X 1.5

184. ASSY. SHIFTING LINK

185. EXTENSION ARM

186. BUSH EXTENSION ARM

13

GEAR BOX G-76

TECHNICAL SPECIFICATIONS

Model G-76 5/3.87 with overdrive

Type : Synchromesh on all gears five forward (including overdrive) & one Reverse

Gear Ratio :

I - 3.87

II - 2.22

III - 1.37

IV - 1.00

V - 0.82

Rev. - 3.4

Oil Capacity - 1.6 liters

Change frequency :

If multi grade 80W 90 API GL 4 is used : 1st change at 10,000 km, 2nd change at 40,000 km & thereafterevery 40,000 km.

If synthetic oil 75W 90 API GL 4 is used : 1st change at 40,000 km, 2nd change at 1,20,000 km & thereafterevery 80,000 km.

IMPORTANT CHECKS AND ADJUSTMENTS

For securing main shaft nut; collar to be staked in the slot. Tightening Torque : 24 to 28 mkg.(Telco make)

0.05 to 0.15 mm end play to be maintained only on drive shaft side.

Distance from rear cover half outer wall to front end of 2nd gear on main shaft 197 + 0.1 mm.

Counter shaft Taper roller half bearing - 0.00 to 0.03 mm pre load (only on front side).

Distance from rear cover outer wall to 3rd gear rear side on counter shaft : 198 + 0.1 mm.

Dimension between drive shaft synchronizing face to engaging gear 3rd - 4th front face : 11.1 + 0.1

Engaging gear to be free from play.

Use sealing compound Maxifix s-758 Dunlop or Duraplex 120 for sealing plugs.

Gap between synchro cone and mating gear = 1+0.3 mm

Tightening torque of drain plug - 5 mkg

Tightening torque of level plug - 2.5 mkg.

Gear Lever Knob

14

GEAR BOX G-76

LIST OF SPECIAL TOOLS

Sr.No. Tool Description Part Number

1 Handle - For drifts 2640 5890 35 11

2 Holder - For main shaft coupling flange (Telco) 2651 5890 35 11

3 Puller - For taper roller bearing counter shaft 2654 5890 26 04

4 Drift - For drive shaft taper roller bearing 2654 5890 26 05

5 Drift - For counter shaft taper roller bearing 2654 5890 26 06

6 Drift - For rear cover oil seal 2654 5890 26 07

7 Puller - For drive shaft & main shaft taper roller bearing 2654 5890 26 12

8 Mounting plate 2654 5890 26 13

9 Drift - For main shaft 2nd speed spacer 2654 5890 35 11

10 Puller - For main shaft 2nd speed spacer 312 589 25 33

11 Holder for coupling Yoke (Spicer make) 2698 5890 3505

or 2698 5890 4102

12 Socket for end yoke nut (Spicer make) 2698 5890 4101

13 Puller 2654 5890 2609

15

GEAR BOX G-76

REMOVAL OF GEAR BOX FROM VEHICLE

Place chocks on wheels.

Disconnect battery terminals, electrical connections of starter motor and remove starter motor.

Remove rubber bellow from collar of base plate . Loosen lock nut or spacer (in case of Tatamobile) and removegear shift lever knob . Take out rubber bellow.

Remove screws and take out clamping plate of the rubber bellow - bottom.

Disconnect exhaust pipe from manifold end and main muffler.

For 4x2 vehicles

Disconnect propeller shaft from gear box end and remove center bearing mounting bolts.

Slide the propeller shaft side ways and support it suitably.

Loosen nylock nuts and washer of extension arm support bracket and take it out.

For 4x4 vehicles

Disconnect extension arm support bracket from transfer case housing.

Disconnect electrical connector of electrical shift motor and speed sensor.

Disconnect electrical connector of vehicle speed sensor, In case of petrol engine.

Disconnect front and rear propeller shaft at transfer case end.

Slide the propeller shaft side ways and support it suitably.

Remove circlip from both ends of shift link and take it out along with teflon washers

Remove circlip and take out pin along with Teflon washer to disconnect extension arm from extension armbracket . Remove extension arm assembly.

Disconnect and remove clutch slave cylinder from clutch housing.

Disconnect speedo cable and connector from reverse indicator switch.

Remove clutch housing front sheet metal cover.

Loosen and remove clutch housing mounting bolts.

Loosen and remove gear box adapter housing support - Rear mounting bolts. (4x2) / adapter housing (4x4)

Lift the gear box (4x2) / transfer case, gear box assembly (4x4) from rear and support the engine suitably.

Remove cross member supporting gear box, from the chassis.

Pull out gear box (4x2) / gear box along with transfer case (4x4) to disengage drive shaft from the clutch platesplines.

Lower the assembly carefully.

Loosen the adaptor housing bolts and separate gear box and transfer case. (4x4)

16

GEAR BOX G-76

DISMANTLING OF GEAR BOX

(The gear box is removed from the vehicle)

Remove clutch release bearing and fork. Fig.1

Remove clutch housing by loosening nuts. Fig. 2

Mount the gear box on drive shaft end face on workstand (Pt. No. 2573 5890 37 01) fitted with adapterplate (Pt.No. 2654 5890 2613). Drain the oil.

Remove breather (13). Remove reverse light switch(129) Fig. 3

Unscrew nuts and loosen extension arm bracket (150)Fig. 4

Fig. 4

Fig. 3

Fig. 2

Fig. 1

17

GEAR BOX G-76

Remove spring clip (170) and push out cylindrical pin(171). Fig. 5

Pull out shifting yoke (169) from selector & shiftershaft.

Pry out oil seal (116) from selector and shifter shaft.Remove spacer (115)

Hold the coupling flange (44) with the holder, Pt.No.2651 5890 35 11. ( for Telco make)

Un-stake and remove main shaft nut (45). Pull outcoupling flange. Fig. 6

Unscrew nuts (65) and take out Assy. gear case cover- Rear (68). Take out main shaft and counter shaftplay adjusting shims (10a & 70) from cover and keepthem properly. Fig. 7

Take out speedo drive gear (42) from main shaft (46)Fig. 8

Fig. 8

Fig. 7

Fig. 6

Fig.5

18

GEAR BOX G-76

Mount the gear box with up side down such that driveshaft is facing upwards. Fig. 9

Loosen screws and pull out Front cover bearing tube (2)Fig. 10

Loosen nuts and remove Assy. gear case cover - Front (8).Take out main shaft & Counter shaft bearing playadjusting shims (10&70a) from cover and keep themproperly. Fig. 11

Loosen and take out reverse Idler shaft mounting screw(54) from housing - Front half. Fig. 12

Fig.12

Fig.11

Fig. 10

Fig. 9

19

GEAR BOX G-76

Pull out plug (91) and then take out detent (89) alongwith spring (90) Fig. 13

Loosen nuts of housing - Front half (77) and separateout Front half. (If required, use puller Pt. no. 26545890 2609) Refer fig. 14 and 15

Separate out drive shaft assy. (1) from housing - Fronthalf. Fig. 16

Fig. 16

Fig. 15

Fig. 14

Fig.13

20

GEAR BOX G-76

Loosen mounting screw (52) and remove Reverse Idlergear retainer plate (86) Fig. 17

Loosen another mounting screw (52a) of Reverse Idlergear shaft. Fig. 18

Remove Assy. Reverse Idler Shaft (82) from housing- Rear half. Fig. 19

Remove pin (96) and remove swing lever (95)Fig. 20 (For gear box with 4 gate shifting)

Remove reverse shifter shaft (94)

Fig. 20

Fig.19

Fig. 18

Fig. 17

21

GEAR BOX G-76

Remove socket with allen key (126) and take outlocating piece (128) Fig. 21

With suitable punch, press out spiral pin (92) fromselector & shifter finger (93). Fig. 22

Take out selector shaft (112) from bottom.

Press out spiral pin (124) of 3rd/4th shifter fork.Fig. 23

Loosen and remove screws (144) of detent cover (140).Remove springs

(141 & 142) and balls (138) Fig. 24

Fig. 24

Fig. 23

Fig. 22

Fig. 21

22

GEAR BOX G-76

Take out shifter shaft 3rd/4th (118) along with interlock pin (146) Fig. 25

Take out main shaft assembly along with the countershaft and shifter shafts from the gear box housing -Rear half. Fig. 26

Note :Ensure that engaging sleeve does notjump out of engaging gear.

Take out inter lock balls (138a) Fig. 27

Separate out counter shaft assembly and shifter shaftsfrom main shaft assembly.

Fig.27 (For 4 gate gear box)

Fig. 26

Fig. 25

Inter lockballs

138

138a

23

GEAR BOX G-76

DIS-ASSEMBLY

DIS-ASSEMBLY OF DRIVE SHAFT Refer Fig. 28

Remove synchro cone (17)

Remove needle roller bearing (7)

Remove thrust bearing (6), spacer (5) and compressionspring (4).

Remove taper roller bearing inner race (11) with thehelp of puller Pt.No. 2654 5890 26 12. Fig. 29

DIS-ASSEMBLY OF MAIN SHAFT

Hold the main shaft assembly (46) such that driveshaft end is upward. Fig. 30

Remove snap ring (15) and spacer (16) Fig. 31

Fig. 31

Fig. 30

Fig. 29

Fig. 28

24

GEAR BOX G-76

Take out 3rd speed gear (23) along with 3rd/4th shiftersleeve (18) and engaging gear (22). Fig. 32

Remove needle roller cage (24).

Gently separate out shifter sleeve from engaging gearand remove carriers (20), springs (19) and balls- 5 mm dia. (21).

Separate out synchro cone (17a)

Hold the shaft firmly and pull out bush (25) along withspacer (27) and 2nd speed gear (29) with the help ofpuller. Pt.No. 312 589 25 33. Fig. 33

Remove spacer locking ball - 3 dia. (26). Fig. 34

Remove snap ring (31). Fig. 35

Fig. 35

Ball(Spacerlocking)

Fig. 33

Fig. 32

Fig. 34

25

GEAR BOX G-76

Take out 1st speed gear assy. (35) along with 1st/2ndshifter sleeve (33) and engaging gear (32). Fig. 36

Remove needle roller cage (36)

Separate out synchro cones (17a)

Gently separate out shifter sleeve from engaging gearand remove springs (19a) carriers (20a) and balls (21a).

Hold the main shaft assembly upside down.

Pull out taper roller bearing inner race (11a) with helpof puller 2654 5890 26 12. Fig. 37

Pull out spacer and 5th assembly (41). Fig. 38

Remove needle roller cage (39).

Separate out spacer (40).

Remove snap ring (31a). Fig. 39

Fig. 39

Fig. 38

Fig. 37

Fig. 36

26

GEAR BOX G-76

Take out reverse gear assembly (37) along withReverse/5th shifter sleeve and engaging gear.Fig. 40

Remove needle roller cage (36a)

Gently separate out shifter sleeve from engaging gearand removing springs (19b) carriers (20b) and balls(21b)

Separate out synchro cones - Reverse (34a)

DIS-ASSEMBLY OF COUNTER SHAFTRefer fig. 41

Hold counter shaft (69) vertically such that 5th constantmesh gear (73) is downwards.

Pull out taper roller bearing inner race (71a) from shaftwith the help of Puller Pt. no. 2654 5890 26 04.

Remove spacer (76) and circlip (75).

Reverse the shaft upside down. Pull out taper rollerbearing inner race (71) from shaft with the help of PullerPt.No. 2654 5890 26 04

Press out constant mesh 5th (73) and 3rd/4th gear(74) using hydraulic press and with proper support.

DISASSEMBLY OF REVERSE IDLER GEAR SHAFTRefer fig. 42

Remove snap ring (83)

Take out Reverse Idler gear (85) along with roller ring(84) from Reverse Idler gear shaft (82).

Remove other snap ring (83a)

Fig. 42

Fig. 41

Fig. 40

27

GEAR BOX G-76

DISASSEMBLY OF GEAR BOX HOUSING - REARHALF

Loosen bearing block locking fit bolt (99) and removebearing block (98). Fig. 43

Remove torsion spring (111) from selector lever pin(109) and take out torsion spring along with tubularspacer (110)

Remove selector lever (108) along with roller (107)from housing. Fig. 44

Unscrew plug (135) and remove spring - Detent plate5th gear (134). Unscrew plug (135a) and remove plunger- Reverse gear detent (137) along with spring (136).Fig. 45 (only for 4 gate gear box)

Unscrew mounting screws (130) and take out pressureplate - reverse speed (132) along with pressure plate5th gear (133).

Loosen and remove Hex. screw (102) along with nut(105), spr. washer (104) and bright washer (103).Remove roller - detent plate (106), if required.

Disconnect pressure plate 5th gear from pressure plate- Rev. speed.

Fig. 45

Fig. 44

Fig. 43

28

GEAR BOX G-76

DIS-ASSEMBLY OF GEAR CASE COVER-FRONT

Remove oil seal (3) with suitable punch.Press out dowel pins (12), if required.

DISASSEMBLY OF GEAR CASE COVER - REARRefer fig. 46

Remove main shaft oil seal (43) from assy. gear casecover rear (68) with suitable drift.

Unscrew and remove assy. threaded plug (50). Removeoil seal speedo shaft (51).

Pull out plug speedo drive (47). Press out shaft speedodrive (49) with suitable punch. Remove speedo drivegear (48).

INSPECTION

Inspect inside of synchro cone for wear

Inspect the synchro cone teeth and matching teethon gear for wear (rounded off). Fig. 47

Inspect the gear hub thrust surface for wear.

Inspect the cone surface for wear on 1st, 2nd, 3rd,4th & 5th mainshaft gear; countershaft gears.

Inspect the teeth on all gears for uneven wear, scoring,galling, cracks.

Place the synchro cone on matching gear cone androtate until it stops (approx. 10 to 20 degrees), thenmeasure the clearance between ring and gear.Fig. 48

Check for synchro cone gaps. It should be1 + 0.3 mm.

Fig. 48

Fig. 47

Fig. 46

Wear

Wear

Pressure

Checkgap withfeelergauge

Sectional View

47 48 49 50 51

29

GEAR BOX G-76

Synchro Sleeve and Hub Inspection

Inspect the gear teeth on all synchro hubs and sleevesfor rounded off corners, indicating wear.

Install each hub in its mating sleeve and check forfree movement.

Note :If replacement is required, always replacethe synchro sleeve and hub as a unit.

ASSEMBLY OF SUB - ASSEMBLIES

GENERAL INSTRUCTIONS

The chips collected by the magnetic drain plug mustbe removed at every oil change.

Clean all the parts thoroughly to be assembled.

CHECK

- Shafts for scoring or grooving and spline wear

- Gears for chipped teeth

- Bushes for wear and cracks

- Bearings for wear and cracks by spinning them. Ifthey shake or rattle then they must be replaced.

Change all worn out and damaged parts.

Maintain proper cleanliness while assembling bearingsand oil seals to avoid premature failures.

Lubricate the shaft and seat before assembling oilseals or fitting bearings.

Do not interchange inner and outer races of taper rollerbearings.

Oil seals and gaskets should be changed at the timeof overhaul.

Pay attention to the direction of the oil seal and insertall the way after applying oil to the lips.

Do not reuse dowel sleeve and nyloc nut. Alwaysreplace them with NEW one.

Circlip/snap ring should not have axial play.

Use sealing compound MAXIFIX S-758 DUNLOP orDURAPLEX 120 for sealing plugs and screws.

Use adhesive ANARBOLIC medium duty for fasteners.

Use Grease 3% MO S2 320 for metal/plastic parts.

Use Grease silicon mollycote medium-33 betweenmetal/rubber parts.

Synchro cone gap is to be checked. It should be1+ 0.3 mm. If found less or if the threads are found tobe damaged, replace synchro cone.

Spin the shaft to see the gears are running smoothly.

Engaging gear should be free from play.

30

GEAR BOX G-76

IDENTIFICATION PARAMETERS

ENGAGING GEARS Refer fig. 49

There is a common engaging gear for 1st/2nd (32)and Reverse/5th (32a) application. However, it hasunsymmetrical shank.

Engaging gear for 3rd/4th (22) has symmetrical shank.

SYNCHRO CONES Refer fig. 50

There are three types of synchro cones.

1st/Reverse synchro cone (34)/(34a) is bigger indiameter and having slender dog teeth.

2nd/5th synchro cone (30)/(30a) is also bigger indiameter but having thicker dog teeth.

3rd/4th (17)/(17a) synchrocone is smaller in diameterand having depressions on minor diameter side face.

SHIFTER SLEEVES Refer fig. 51

There are three types of shifter sleeves.

3rd/4th shifter sleeve (18) is without any groove on itsouter diameter.

1st/2nd shifter sleeve (33) is with one groove on itsouter diameter.

Reverse/5th shifter sleeve (38) is having two grooveson its outer diameter.

Fig. 50

Fig. 49

Slender dogteeth.

Fig. 51

2nd / 5th

3rd / 4th

1st / Rev

Rev / 5th 1st / 2nd3rd / 4th

31

GEAR BOX G-76

SHIFTER FORKS Refer fig. 52

There are three types of shifter forks.

1st/2nd shifter fork has the engaging collar at the centre.

3rd/4th shifter fork has step collar and ribs supportingthe engaging collar. Rev./5th shifter fork has theinstalling hole in the centre.

SHIFTER SHAFTS Refer fig. 53

1st / 2nd shifter shaft has two installation holes.

3rd / 4th shifter shaft has inter locking pin in the groovecut at the bottom.

Rev. / 5th shifter shaft has the installing hole near thenotch.

Fig. 53

Fig. 52

Rev / 5th

3rd / 4th

1st / 2nd

Rev / 5th 1st / 2nd 3rd / 4th

32

GEAR BOX G-76

SUB ASSEMBLY OF ENGAGING GEARSRefer fig. 54, 55 & 56

Identify all the gears and needle bearing cages. Thegears are to be assembled in pairs of 1st/2nd, 3rd/4thand Reverse/5th

Keep gear such that dog teeth are facing upwards.

Fit proper synchro cone. Fit proper engaging gear oversynchro cone, Fit other pair of gears.

Note :While assembling 1st/2nd engaging gear thelonger shank to be on 2nd gear side. In the same wayfor Reverse/5th engaging gear, the longer shank to beassembled towards reverse gear.

Locate 3 Nos. carriers in slot of engaging gear suchthat chamfer over carrier is facing outwards. Placesprings & balls at seat of carrier with help of grease.

Assemble proper shifter sleeve over engaging gear,pressing all the balls simultaneously.

Note :While assembling 3rd/4th gear, the shifter sleeve(18) without groove to be fitted with broader sidetowards 3rd gear.

While assembling 1st/2nd gear, single groove sideof shifter sleeve (33) is to be assembled towards2nd gear.

In Reverse/5th gear assembly, fit double groove sideof shifter sleeve (38) towards reverse gear.

Fig. 56

Fig. 55

Fig. 54

Gear 3rd/4th assy.

Gear 1st/2nd assy.

Gear Rev. / 5th assy.

33

GEAR BOX G-76

SUB ASSEMBLY OF MAIN SHAFT

Hold the main shaft (41) vertically keeping the couplingflange end upwards.

Slide reverse gear sub-assembly (37) on main shaftalong with needle roller cage (36a) and engaging gear(32a) keeping engaging gear upwards. Fig. 57

Fit snap ring (31a) Select snap ring such that it issnug fit in the groove. Snap rings are available inthicknesses ranging from 1.7 to 2 mm in the step of0.05 mm. Fig. 58

Slide the 5th gear sub-assembly (41) along with theneedle roller cage (39) and synchro cone (30a) suchthat the synchro cone is towards engaging gear.Fig. 59

Slide spacer (40)

Press taper roller bearing inner race (11a) with help ofdrift, Pt.no.2654 5890 26 05 such that taper is upwards.Ensure that bearing inner race is butting against spacer.Fig. 60

Fig. 59

Fig. 58

Fig. 57 Fig. 60

34

GEAR BOX G-76

Hold the main shaft vertically in coupling flange withup side down.

Slide the 1st gear sub-assembly (35) along with theneedle roller cage (36) and engaging gear 1st/2nd (32)over main shaft such that engaging gear is upwards.Fig. 61

Select suitable snap ring (31) and fit it over main shaftgroove. Snap rings are available in the thicknessranging from 1.7 to 2 mm in the step of 0.05 mm.Fig. 62

Slide the 2nd gear sub-assembly (29) over main shaftalong with the needle roller cage (24a) and synchrocone (30) such that synchro cone facing downwards.Fig. 63

Locate 3 mm Dia. locking ball (26) at seat on mainshaft with help of grease. Slide spacer (27), aligningnotch with the locking ball. Ensure that oil pocket overthe spacer is facing upwards i.e. towards 3rd gear.Fig. 64

Fig. 64

Fig. 63

Fig. 62

Fig. 61

oil pocket

locking ball(spacer)

35

GEAR BOX G-76

Push the bush (25) with the help of drift,Pt.No. 2654 5890 35 11. Fig. 65

Note :The spacer has to be heated to 100 to 120degree Centigrade before assembly.

Slide 3rd gear sub-assembly (23) along with the needleroller cage (24) and engaging gear 3rd/4th (22) overmain shaft keeping engaging gear upwards. Fig. 66

Slide spacer ring (16) over main shaft. Fig. 67

Select suitable snap ring (15), which will fit snugly.Snap rings are available from 2.0 to 2.4 mm in thestep of 0.1 mm. Fig. 68

Measure the dimensions for the selection of shims.(As per procedure mentioned).

Shims (10/10a) are available in thickness of 0.05,0.125, 0.240 & 0.5 mm.

Fig. 68

Fig. 67

Fig. 66

Fig. 65

36

GEAR BOX G-76

SUB ASSEMBLY OF COUNTER SHAFTRefer fig. 69

Heat the constant mesh 3rd/4th gear (74) to 100-120deg.C and press over counter shaft (69) with propersupport in such a way that bigger gear i.e. 4th is facingupward. Fit circlip (75).

In the same way fit 5th gear (73) over other side suchthat longer boss is facing upwards. Ensure properabutment of gear on the counter shaft.

Press inner race of taper roller bearing (71) overcounter shaft 5th gear side end with help of drift, Pt.No.2654 5890 26 06 and handle Pt.No. 2640 5890 35 11.Place outer race over it.

Reverse the assembly, slide spacer (76) and pressanother taper roller bearing inner race (71a). Place outerrace over it.

SUB ASSEMBLY OF DRIVE SHAFT

Press inner race of taper roller bearing (11) with thehelp of drift Pt.No. 2654 5890 26 05. Fig. 70

Fit compression spring (4), spacer (5) of requiredthickness, thrust bearing (6) and roller cage (7) in driveshaft bore. Fig. 71

Select spacer thickness as per procedure given.

SUB ASSEMBLY OF REVERSE IDLER GEARSHAFT Refer fig. 72

Fit snap ring (83a) over R.I. gear shaft (82).

Slide roller ring (84) along with R.I. gear (85) over shaft.Fit another snap ring (83).

Fig. 72

Fig. 71

Fig. 70

Fig. 69

37

GEAR BOX G-76

MEASUREMENT OF CONTROL DIMENSIONS (FOR SELECTION OF SHIMS)

OVER THE COUNTER SHAFT

The control dimension to be maintained between Counter Shaft 3rd gear rear 198 ± 0.1mmface and housing face-Rear half.

1.0 Dimensions to be measured Symbol Example

1.1 Measure the dimension between Counter Shaft 3rd gear rear face and A 200.00taper roller bearing outer race face. Fig. 76 and 77

1.2 Measure the rear cover depth. Fig. 73 and 76 B 2.30

1.3 Difference A-B C 197.70

1.4 Shims required : 198 - C D 0.30

Fig. 74Fig. 73

OVER THE MAIN SHAFT

The control dimension to be maintained between Main Shaft 2nd gear 197±0.1mmshoulder face front and housing face - Rear half


2.1 Measure the dimension between Main Shaft 2nd gear shoulderface front and taper roller bearing outer race face Fig. 75 and 76 E 202.00

2.2 Measure the rear cover depth Fig. 74 and 76 F 5.50

2.3 Difference E - F G 196.50

2.4 Shims required 197 - G H 0.50

FB

38

GE

AR

BO

X G

-76

Fig. 76

Fig. 75

F

B

A

E

E

198 + 0.1

Controlled with rear cover shim.

197 + 0.1 (Controlled with rear cover shim)

A

Fig. 77

39

GEAR BOX G-76

OVER THE DRIVE SHAFT

During measurement, remove compression spring (4). Check for the spacer of measured thickness, thrustbearing and needle roller cage in drive shaft bore. Place drive shaft assembly over main shaft assembly.

The control dimension to be maintained between Drive Shaft synchro 11.1 ± 0.1 mmring front face to engaging gear 3rd/4th shoulder face

3.0 Dimensions to be measured. Symbol Example

3.1 Place Drive Shaft over Main Shaft Assy. with spacer of measured I 4.50thickness

3.2 Measure the dimension between engaging gear 3rd/4th shoulder faceto Taper Roller bearing outer race face on main shaft Fig.78 and 79 J 252.00

3.3 Measure the dimension between Drive Shaft synchro ring frontface to Taper Roller bearing outer race face on main shaft Fig.78 and 79 K 262.80

3.4 Difference K-J L 10.80

3.5 Incremental spacer thickness required 11.1-10.8 M 0.50

3.6 Spacer thickness required 4.50 + M N 5.00

Fig. 78

K

J

40

GE

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11.1+0.1

K

J

★ Controlled with thrust bearing spacer

11.1+ 0.1

J

K

Fig. 79

Fig. 79 A

★

41

GEAR BOX G-76

COUNTER SHAFT SHIM SELECTION AT FRONT COVER

Assemble the gear box without compression spring and without Front Cover

5.0 Dimensions to be measured SymboI Example

5.1 Measure Front Cover depth along with the gasket Fig. 81 and 83 T 4.75

5.2 Measure counter shaft bearing projection over housing face Fig. 83 U 4.50

5.3 Difference T-U V 0.25

5.4 Shims required (Maintain pre-load of 0.00 to 0.03 mm) V+0.03 W 0.28

Fit compression spring and Front cover with shims ‘W’ and check for free rotation.

DRIVE SHAFT SHIM SELECTION AT FRONT COVER

Assemble the gear box without compression spring (4) and without Front Cover.


4.1 Measure the Front Cover depth along with the gasket Fig. 80 and 83 P 5.75

4.2 Measure drive shaft bearing projection over housing face Fig. 83 Q 5.50

4.3 Difference P-Q R 0.25

4.4 Shims required (Maintain end play of 0.05 to 0.15 mm) S 0.15

Fit Front Cover with shims ‘S’ and check axial play at coupling flange. The play must be with in 0.07 to 0.10mm. Change shims if required, to get required play. Remove Front half and re-assemble compression spring.

Fig. 81

T

Fig. 80

P

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P/Q

T/U

Fig. 83

T

U

Fig. 84

P

Q

1010a

Fig. 82

43

GEAR BOX G-76

SUB ASSEMBLY OF GEAR BOX HOUSING COVERFRONT

Press dowel pins (12) to bearing tube, if removedearlier. Fit bearing tube to the cover.

Push in oil seal (3) with help of drift Pt.No. 2654 589026 07 and handle Pt.No. 2640 5890 35 11. Fig. 85

SUB ASSEMBLY OF GEAR CASE COVER REARRefer fig. 86&87

Fit oil seal (43) with the help of drift, Pt.No. 2654 589026 07 and handle 2640 5890 35 11.

Fill 3% grease Mo S2 320 in the pocket between mainlip and dust lip of oil seal.

Keep speedo drive gear (48) inside the cavity thenpush in speedo shaft (49) such that cable end goestowards tapped hole side.

Fit oil seal - speedo shaft (51) in the threaded plug -speedo shaft (50) keeping lip side outwards. Tightenplug in the housing.

Press plug - speedo drive (47) in housing from otherside. Ensure gap of 1 mm between plug face tospeedo shaft end.

Fig. 87

Fig. 85

47 48 49 50 51

Fig. 86

44

GEAR BOX G-76

Fit locating piece reverse shifter shaft (128) in thehousing with the help of socket head cap screw (126)and spring washer (127) such that it sits properly.Fig. 88

Fit spacer (115) and oil seal (116) in housing beforeshifter and selector shaft. Ensure proper direction ofoil seal lip. Fig. 89

ASSEMBLY OF SHIFTER AND SELECTOR SHAFTSRefer fig. 90

There are three shifter shafts, one selector shaft andone shifter shaft for reverse speed.

Assembly of 1st/2nd shifter shaft

This shaft (119) is having two Nos. holes for spiralpins approximately at the centre of the shaft.

Hold shaft horizontally keeping notch upward andtowards yourself.

Slide shifter dog 1st/2nd (122) over shifter shaft fromother end such that shaft relieving radius is at top andtowards right side.

Align shifter dog with outer hole of shaft and pressspiral pin (124).

Select shifter fork 1st/2nd (121) which is havingengaging collar at centre and slide over shaft. Align itwith shaft hole and press spiral pin (124)

Assembly of Reverse / 5th shifter shaft.

This shaft (117) is having hole nearer to notch.Corresponding shifter fork (120) is almost symmetricaland there is no step in the collar at the flange.

Slide shifter fork on shaft such that engaging collar isfacing outwards. Fit spiral pin (124).

Note : Assembly of 3rd/4th shifter shaft (118) whichis having through hole in notch for inter lockingpin, to be done at the time of final assembly.

Fig. 90

Fig. 89 (For 4 gate shifting gear box)

Fig. 88

116

Oil seal

115

Spacer

Sectional View

45

GEAR BOX G-76

SUB ASSEMBLY OF GEAR BOX HOUSING - REARHALF Refer fig. 91

Mount gear box housing - rear (80) on the work stand.Check for all mounting studs.

Fit roller - detent plate (106) in pressure plate 5th gear(133), if removed earlier.

Fit pressure plate 5th gear above pressure plate -Reverse speed (132). Fit hex. screw (102), brightwasher (103), spr. washer (104) and nut (105).

Fit pressure plate Reverse speed in the housing - rear.Tighten hex. screw (130) with spr. washer (131)

Fit main shaft and counter shaft bearing outer racesin the housing half.

Assemble plunger Reverse gear detent (137) alongwith spring (136) in the housing such that its taperface is towards roller. Tighten threaded plug (135).Ensure correct orientation of detent.

Assemble spring - detent plate 5th gear (134) andtighten threaded plug (135a) Fig. 92

Fit assy. selector lever (108) along with roller selectorlever (107)

Locate straight end of torsion spring (111) in the holeof selector lever pin and place tubular spacer (110) inthe torsion spring.

Locate bearing block (98) over torsion spring andtighten hex bolt (99) along with bright washer (101)and spring washer (100) in the housing. Fig. 93

Fig. 93

Fig. 92

Fig. 91

46

GEAR BOX G-76

ASSEMBLY OF GEAR BOX

Place shifter fork assembly 1st/2nd and Reverse/5thover main shaft assembly at its proper place, keepingnotches towards coupling flanges side.

Place shifter fork 3rd/4th (123) alone without shaft atits place over main shaft sleeve such that its collar isfacing outwards.

Keep counter shaft assembly aligned with main shaft.

Insert two Nos. ball (138a) in holes of shifter shaftbore in housing. Use grease for keeping them inposition. Fig. 94

Hold and place main shaft assembly along with countershaft assembly and shifter fork assembly in positionin the housing - Rear. Fig. 95

While inserting shifter shafts in the housing, ensurethat interlocking balls are not displaced.

Fit interlock pin - 12.8 mm length (146) in shifter shaft3rd/4th (118). Insert shaft through the shifter fork. Alignshaft with hole of fork and then press spiral pin (124).Fig. 96

Place 3 Nos. ball - 8 mm dia. (138) and detent springin holes of housing. Detent spring (142) is to lock 1st/2nd & 3rd/4th shifter shafts where as short and stiffdetent spring (141) is to be used for Reverse/5th shiftershaft. Fig. 97

Fix gasket (139) to detent cover (140) and tighten hex.screws (144) along with spr. washer (145). Fit rollers 4Nos. (113) over pins (114) of selector shaft (112).

Fig. 97

Fig. 96

Fig. 95

Fig. 94

Sectional View

Inter lockballs

138

138a

47

GEAR BOX G-76

Slide shifter shaft - Rev. speed (94) in the housingbore. Fig. 98

Locate selector & shifter finger (93) between shifterdog - 3rd/4th notch and reverse speed shifter shaftunder cut.

Insert selector shaft from bottom through selector lever(108) aligning rollers with its splines. Then pass itthrough selector & shifter finger and ensure that notchat end is facing towards detent (89). (To be fittedafterwards). Fig. 99

Align hole of selector shaft and selector & shifter finger.Fit spiral pin (124). Fig. 100

Locating swing lever (95) between under cut of reverseshifter shaft and shifter shaft Reverse/5th. Ensurethat notch on the lever is at the top and towardsreverse shifter shaft. Fig. 101

Fit circlip (97) to pin (96), if removed earlier. Insert pinthrough bearing block and swing lever.

Fig. 101

Fig. 100

Fig. 99

Fig. 98

48

GEAR BOX G-76

Fit Reverse Idler gear shaft assy. (82) in the housingsuch that reverse gear collar is at top. Fig. 102

Tighten hex. screw (54a) along with bright washer (55a)and spr. washer (56a) to hold Reverse Idler shaft inthe housing - rear. Fig. 103

Align retainer plate (86) in Reverse Idler gear collar,simultaneously locating its pin in housing. Tighten hex.screw (52) along with spr. washer (53) in the housing.Fig. 104

Fit linear bearing (28) in the housing - Front, if removedearlier.

Place drive shaft. Fig. 105

Fig. 105

Fig. 104

Fig. 103

Fig. 102

49

GEAR BOX G-76

Apply shellac and put gasket (79) over housing partingsurface. Place gear box housing - Front (77) over therear half aligning dowel pins and gently tap it withmallet.

Put hex. nuts along with plain and spring washer.Tighten all nuts evenly. Fig. 106

Apply adhesive gasket eliminator over front cover faceand fit it over housing front.

Place measured shims of drive shaft and countershaft at the seat of front cover.

Put hex. nuts along with bright washer and springwasher and tighten them. Fig. 107

Check free movement of roller of detent (89). Carefullyfit detent in a bore of housing - front, keeping rollerhorizontally and ensure that it is located properlyover selector shaft notch. Fig. 108

Fit detent spring (90) and then press plug (91)

Slide speedo drive gear over main shaft. Fig. 109

Fig. 109

Fig. 108

Fig. 107

Fig. 106

50

GEAR BOX G-76

Apply adhesive gasket eliminator over rear cover face.Place measured shims of main shaft and counter shaftat the seat of rear cover. Fit rear cover to housing half- rear. Put hex. nuts (65) along with bright washer (66)and spring washer (67) and tighten them. Fig. 110

Press coupling flange over main shaft rear end. Fitcollared hex. nut and tighten it to the specified torqueof 24-28 mkg. Fig. 111

Stake the collar in undercut with suitable chisel tosecure the nut. (For Telco make)

Slide washer (115) over selector shaft in the housingand then press oil seal (116) with suitable drift.

Fit bracket - extension arm (150) to the housing.Fig. 112

Apply grease on spherical seat of shifter shaft end.

Check for condition of bush shifting yoke (176).

Slide shifting yoke (169) over spherical seat of shiftershaft. Align its hole with shaft hole such that projectedend of the bush is towards right hand side.

Fit cylindrical pin (171). Slide spring clip (170) overthe under cut of shifting yoke. Fig. 113

Fit oil drain plug (78), breather (13) and reverse indicatorswitch (129).

Fig. 112

Fig. 111

Fig. 110 Fig. 113

51

GEAR BOX G-76

ASSEMBLY OF GEAR SHIFT LINKAGERefer fig. 114

Check condition of bush fitted at the bottom end ofgear shift lever.

Apply light coat of grease over gear shift lever ballseat and also on inner surface of bush (162). Pressbush over ball seat.

Slide ‘O’ ring (161) over bush. Then press bush alongwith the gear shift lever inside the housing bore ofextension arm (151) such that arrow marks on thebush are perpendicular to the arm.

Lock the bush by turning it clockwise by 90 deg.

Slide rubber bellow (163) over bottom end of gear shiftlever and fit over collar of extension arm bore housing.

Press bush (176) from one side in bore at front end ofextension arm. Fill some grease inside bore from otherside and then press another bush (176) inside the bore.

Smear light coat of grease over outer surface of bushand bracket flanges.

Align front end of extension arm between flanges ofextension arm bracket (150). Then insert pin (178) alongwith Teflon washer (177) through flange and bracketbush hole. Slide another teflon washer over pin fromother end and then fit circlip. (175).

Check both pin ends of shift link (172). Apply greaseover pins and also inside the bushes of shifting yoke(169) and gear shift lever bottom end.

Align gear shift lever such that its bend is towardsrear side.

Fit spring washer (173) and plain washer (174) overboth pins of shift link.

Fit shift link end with longer pin in shifting yoke boreand other end with smaller pin in gear shift lever bottombush bore simultaneously from LH side.

Fit plain washer (174) & spring washer (173) and thenfit circlip over both pins.

Slide rubber seal (160) of extension arm to tunnel overextension arm rear end bore housing.

Slide rubber bellow (154) over gear shift lever knob.

Fit hex. lock nut (153 or spacer for Tatamobile) andthen gear shift lever knob at threaded end of gearshift lever. Fix position of knob aligned with the directionof driving. Tighten hex. lock nut.

Check movement of gear shift lever for properengagement of all gears.

Fill recommended oil to specification up to plug level.Tighten oil filler plug (81) to 2.5 mkg.

Fig. 114

52

GEAR BOX G-76

INSTALLATION OF GEAR BOX ASSEMBLYON VEHICLE

Note :Take guidelines from the write up on removal ofgear box.

Fit clutch housing to gear box front face. Fig. 115

Fit clutch release bearing and release fork. Fig. 116

Lift and mount the gear box at cylinder block face,aligning drive shaft splines with clutch plate hub splinesand clearing gear shift lever through opening providedon the cab.

Tighten all mounting bolts of clutch housing.

Apply grease over supporting pin of extension armand also inside rubber bush of extension arm support.Slide support over pin.

Fit extension arm support (164) on cross member.

Tighten nylock nut (167) along with washer (166) suchas to maintain a clearance of 10 mm betweenextension arm stud end and propeller shaft.

Fit

- Clutch slave cylinder and its piping.

- Speedo cable

- Reverse indicator switch connector Fig. 117

- Propeller shaft

Fix rubber seal in its seat over tunnel cut out and overplate, tighten screws along with washer.

Slide rubber bellow over collar of cover plate.

Fig. 117

Fig. 116

Fig. 115

53

GEAR BOX G-76

TROUBLE SHOOTING

Sr.No. Problem Possible Cause Remedy

1. Hard and / or Check the synchro cone wear Change synchro cone and gear.noisy gear shifting Insufficient lubricant, improper Fill to proper lever withlinkage. grade or quality of oil. recommended oil. Rectify

leakage, if any.Defective clutch linkage or gear Rectify/adjust clutch/gear shiftlinkageDamaged main shaft spigot Replace damaged parts.roller baring.Worn or wrapped gear shift fork / Repair or replace the damagedshifter rods etc. parts.Shifter sleeve tight on matching Repair or replacegears.

2. Slips out of gear The groove in the gear shifter rod Replace the shifter rod.towards front is shallow.The pressure spring is weak or Replace the pressure spring.broken.Dog teeth on gears worn out Replace the affected gears.Shifter sleeve worn out Replace the affected sleeveShifter fork thrust pad/surface worn. Replace the damaged parts.Excess end play in drive, main or Replace / repaircounterGear box mounting loose. Tighten mounting.

3. Gears sticky Insufficient lubricant, improper Fill the proper lever withgrade or quality. recommended oil, rectify leakageif anySliding shifter sleeve synchro Repair / replace.cone jammed.

4. Noisy gears Insufficient lubricant, improper Rectify leakage if any fill tograde or quality proper level with recommended oilExcess end play in drive, main or Repair / replacecounter shaft.Gear box out of line with clutch Loosen gear box mounting.housing. Realign and secure.

5. Loss of drive Defective clutch Rectify / replaceStriped teeth on affected meshing Replace damaged parts.gears.

6. Repeated gear failure Breather chocked Clean and refit breathe.Insufficient or improper grade or Fill to proper level with recommendedquality oil after stopping leakages.Defective clutch Adjust or replace clutch.Improper assembly or installation of Gear box front face must lie flat flushgear box, Incorrect location of shifter with mating clutch housing face.sleeve on the main shaft during Tighten bolts only after the gear is inassembly. place.

55

GEAR BOX G-76

G-76 Gear BoxIMPROVEMENTS -SUPPLEMENT

Please refer this supplement in conjunctionwith the assembly/dismantling procedureexplained in G-76 Gear Box group in thismanual.

Basic overhauling procedure remains sameas explained for G-76 (4 gate) Gear Box.

This supplement gives details of majormodifications incorporated on G 76 GearBox till Nov. 2003.

Par t Nos. o f modi f ied & unmodi f iedcomponents, precautions to be taken whilefitting modified components etc. have beenexplained.

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DIRECTION OF DRIVING

Fig. 1 G-76 GEAR BOX WITH INLINE SHIFT EXPLODED VIEW

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Fig. 2 GEAR SHIFTING LINKAGE (IN LINE SHIFTING)

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Fig. 3 GEAR BOX WITH DUAL CONE SYNCHRONISERS ON 1st & 2nd GEARS

60

GEAR BOX G-76

Fig. 5

Fig. 4

Procedure to remove inhibitor assy. :

The inhibitor is located in housing front half.Fig 4

Loosen allen screw & take out inhibitor assy.Fig. 5 & 6

Fig. 6

61

GEAR BOX G-76

Fig.9

Fig.8

Fig. 7

The detent for assy. selector & shifter shaft isfixed with screw plug type arrangement. Fig. 7& 8

To remove detent unscrew & take out detentspring & central detent assy.

The assy. selector shifter shaft grooves aremodified for smoother engagement. Fig. 9 New Version

Old Version

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GEAR BOX G-76

G-76 Gearbox with Rev/od in line shift pattern - List of parts modified / deleted :

No. Old Part No. Part Description New Part No. Part Description Old PartStatus

1. 2684 2651 8204 Pressure Plate Rev 2684 2651 8202 Pressure Plate Rev Modified

2. 2684 2651 6707 Pin Swing Lever -- Pin Swing Lever Deleted

3. 2684 2670 7910 Shifter Shaft 3/4 2684 2670 7916 Shifter Shaft 3/4 Modified

4. 2684 2670 7903 Shifter Shaft R/OD 2685 2670 7917 Shifter Shaft R/OD Modified

5. 2684 2680 0108 Assy. G. S. Knob 2684 2680 0174 Assy. G. S. Knob Modified

6. 2684 2651 3404 Rev. Plunger -- Rev. Plunger Deleted

7. 2684 2651 8203 Swing Lever -- Swing Lever Deleted

8. 2684 2651 8704 Rev. Plunger Spring -- Rev. Plunger Spring Deleted

9. 2684 2651 9901 Locating piece -- Locating piece Deleted

10. 2684 2651 9905 Bearing Block 2684 2651 9906 Bearing Block Modified

11. 2684 2670 7909 Shifter Shaft Rev 2684 2651 0114 Assy. Inhibitor Modified

12. 2684 2651 9903 Selector Shifter Finger 2684 2651 5106 Selector Shifter Finger Modified

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GEAR BOX G-76

GEAR BOX – SHIFTER SHAFT

Flat end introduced for smoother & precise Gear shifting

Introduced from Feb 2003.

ExistingSpherical end

GEAR BOX - DRIVE SHAFT

Existing

ModifiedFOR BETTER LUBRICATION

1. OIL HOLE DIA INCREASED FROM1.5 TO 2 mm.

2. NUMBER OF OIL HOLES

INCREASED FROM 6 TO 12

Introduced from October 2002

64

GEAR BOX G-76

GEAR BOX - MAIN SHAFT

GEAR BOX - INHIBITOR ASSEMBLY

GEAR BOX - ASSEMBLY DETENT

GEAR BOX - SYNCHROCONE

Anticarb Paste application on Splines toeliminate chipping.

Introduced from Nov 2002.

Existing Modified

SHORTER VERSION INTRODUCEDFOR BETTER GEAR SHIFTING OF5TH & REVERSE GEAR.

Introduced from Feb 2003.

Existing Modified

Roller type changed to Ball typefor smooth Gear Shifting

Introduced from Feb.2003.

Dog Teeth with unequal Dach chamfer introduced forSmooth shifting of 1st & Reverse Gear.

Introduced from May 2002.

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MODIFICATIONS ON G 76 GEAR BOX APPLICABLE FOR TELCOLINE

RemarksSlNo.

ModificationReasons

forModification

Break point(100 %)

Parts involved

Chassis No DescriptionOld item New item

CautionPart No Qty Part No. Qty

Identifica-tion of new

item

1 Introduction of 9 degreeback taper angle on allgears and shifter sleeve atdog teeth area

To avoid gearslippage

Introduced inSeptember 2001.JYZ 9 16744 forRHD & J2900537 for LHD.

Shifter sleeve1/2nd

2684 2620 4614 1 2684 2620 4622 1 By partnumber only

To be replacedas a set whenswitchingover from 7degreeversion to 9degreeversion.

Parts of 7 degree & 9degree are notinterchangeable.Whenever a particulargear or shifter sleeve isreplaced, it should be withsame angle (either 7degree or 9 degree). Incase a particular gearor shifter sleeve ofsame angle is notavailable, then thatparticular gear, shiftersleeve and other sidegear of relevant sleeveare to be replaced as aset. Manufacture of 7degree componentshave been stopped. Allrequirements to beraised only for 9 degreecomponents.

1st gear 3.87ratio


2nd gear 2.22ratio


Shifter sleeve3/4th


To be replacedas a set whenswitchingover from 7degreeversion to 9degreeversion.

3rd gear 2684 2620 0103 1 2684 2620 0148 1 By partnumber only

Drive shaft 2684 2625 0101 1 2684 2625 0103 1 By partnumber only

Shifter sleeveRev/OD


To bereplaced as aset whenswitchingover from 7degreeversion to 9degreeversion.

Reverse gear 2684 2620 0105 1 2684 2620 0149 1 By partnumber only

OD gear 2684 2620 0115 1 2684 2620 0150 1 By partnumber only

2 Multi grade oil 80 W 90 To enhance oildrain period &longer life ofcomponents

Intoduced inSeptember 2002.MAT 374 50139L 00313 forLHD & JXZ 915468 for RHD.

Nil Nil Nil Nil Nil NA Nil First Oil change at 10000kms. Second oil changeat 40000kms. SubsequentOil changes after every40000 Kms. Earlier typemono grade oil & multigrade oil not compatiblewith each other & henceshould not be mixed.

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RemarksSlNo.

ModificationReasons

forModification

Break point(100 %)

Parts involved




item

3 Inline shiftingarrangement for reverse& OD.

Easy gearshifting & costreduction

Introduced inMarch 2002.CXZ 9 04812 forRHD & C2901911 for LHD.

Pressure plateRev

2684 2651 8204 1 2684 2651 8202 1 By part numberonly. Stopperposition for pin ofselector leverreduced by 5 mm.

Not inter-changeable

In line shifting is 3 gateshifting configuration.

Pin swinglever

2684 2651 6707 1 Nil Deleted

Shifter shaft3/4th

2684 2670 7910 1 2684 2670 7916 1 Slot for shifterf i n g e rextended totravel forward& backward.


Shifter shaftRev/OD

2684 2670 7903 1 2685 2670 7917 1 Slot for Pinswing leverdeleted.


Assy G Sknob

2684 2680 0108 1 2684 2680 0174 1 3 gate shift systemembossed on top.


Plunger 2684 2651 3404 1 Nil Deleted

Swing lever 2684 2651 8203 1 Nil Deleted

Spring 2684 2651 8704 1 Nil Deleted

Locating piece 2684 2651 9901 1 Nil Deleted

Bearing block 2684 2651 9905 1 2684 651 9906 1 Bearing blockdoes not have 6mm dia hole formounting Pinswing lever.


Shifter shaftRev

2684 2670 7909 1 Nil Deleted

Assy Inhibitor NA NA 2684 2651 0112 1 New item.

Selectorshifter finger

2684 2651 9903 1 2684 2651 5106 1 Position oflug to actuatereverse lightswitchchanged.


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RemarksSlNo.

ModificationReasons

forModification

Break point(100 %)

Parts involved




item

4 Qualis type flat end shaftgear box with sphericaldetent

Easy gearshifting & costreduction

Introduced inFebruary 2003.MAT 374 58239L 00815 forLHD & 374 415BWZ 9 02892 forRHD.

Assy hsg for4x2

2684 2610 0129 1 2684 2610 0133 1 Inhibitor holepositionshifted to fronthalf ofhousing.Inhibitormountinghole on rearhalf madeblind.Sphericaldetentthreaded holedia on fronthalfincreased.

To be used asa set only

For Gear shift lever assy1) O-ring 2) Bush, 3)Sintered moulded bushreplaced with newmoulded bush along withcrinkled washer.

Assy hsg for4x4

2684 2610 0130 1 2684 2610 0134 1 Inhibitor holepositionshifted to fronthalf ofhousing.Inhibitormountinghole on rearhalf madeblind.Sphericaldetentthreaded holedia on fronthalfincreased.

Inhibitor assy 2684 2651 0112 1 2684 2651 0114 1 0112 - length- 160mm0114 - length- 70mm

Torsion spring 2684 2651 8710 1 2684 2651 8714 1 only by PartNo

CD spring 2684 2651 8709 1 2684 2651 8715 1 only by PartNo

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RemarksSlNo.

ModificationReasons

forModification

Break point(100 %)

Parts involved




item

Central detent 2684 2651 0102 1 2684 2651 3115 1 0102 - hasroller3115 - hassperical ball

To be used asa set onlyalong withgearbox hsg

Spring fordetent

2684 2651 8701 1 2684 2651 8717 1 8701 - length- 23 mm8717 - length- 41 mm

Plug 2684 2651 6702 1 2684 2651 6501 1 6702 - roundend6501 -threaded withhex head

Sel & shiftershaft 4x2

2684 2670 7913 1 2684 2670 7920 1 7913/19 -sperical end,dull grey colour7920/21 - flatend, blackcoating

Sel & shiftershaft 4x4

2684 2670 7919 1 2684 2670 7921 1

Shifting yoke 2684 2651 3703 1 2684 2651 3706 1 3703 - roundbore at pinjoint, dullgrey colour3706 - flat cutat pin joint,black coating

Bush (extarm)

2684 2671 3403 2 2684 2671 6302 2 3403 - steel,6302 - whiteplastic

“o” ringdeleted

Bush shift link 2684 2651 3409 2 2684 2671 6301 2 3409 - blackrubber, 6301 -white plastic

“o” ringdeleted

Bush shift link 2684 2651 3410 1 Nil 3410 - blackplastic

Deleted

Bush leverbottom

2684 2680 3402 1 2684 2671 6301 2 3402 - notcollared, 6301- collared

“o” ringdeleted

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RemarksSlNo.

ModificationReasons

forModification

Break point(100 %)

Parts involved




item

5 Introduction of unequalDach chamfer on2nd(Single cone)/3rd &Driveshaft

To ImproveGear shift Feel

Introduced inJuly 2003

2nd gear 2.22ratio *

2684 2620 0196 1 2684 2620 0210 1 Un equaldach chamferon syncroring teeth

Inter-changeable

Can be interchanged onone to one basis

3rd gear 2684 2620 0148 1 2684 2620 0212 1 Un equaldach chamferon syncroring teeth

Inter-changeable


Driveshaft 2684 2625 0103 1 2684 2625 0115 1 Un equaldach chamferon syncroring teeth

Inter-changeable


6 Dual syncro cones for1st/2nd gear

To over comehard gearshiftingcomplaints

Introduced inOctober 2003.MAT 374 53149L 00694 forLHD. Yet to beintroduced inRHD version.Allthesemodificationswere introducedas a package.

Inner cone * Not applicable 2684 2620 3828 2 Providedwith 6 lugs &made ofbrass.

New item.Common for1st/2nd gear

For Synthetic Oil, First Oilchange is at 40000 kms &subsequent changes aftercoverage of every 80000Kms. If synthetic oil is notavailable, 80 W 90 oilrecommeneded earlier canbe used with oil drain periodof 40000 Kms. But both oilsshould not be mixed, sincethey are not compatible witheach other. Items with *mark have to be replacedas a set when switchingover to Dual coneversion in unmodifiedgear box. Inner cone,intermediate cone & outercone are available under kitpart no. 2684 2620 0160.Qty/vehicle - 2.

Un equal dach chamferangle for 2nd(Dual cone)gear syncro ring teeth

To eliminatecomplaint ofhitting feelingduring gearshift

Intermediatecone *

Not applicable 2684 2620 3833 2 Providedwith 3 lugs &Made of steel


Synthetic oil 75 W 90API GL4

To over comehard gearshiftingcomplaints & toextend oil drainpriod

Syncro coneouter *

Not applicable 2684 2620 3830 2 Providedwith 6 lugs tomatchcorrespondinglugs in innercone & madeof brass.


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RemarksSlNo.

ModificationReasons

forModification

Break point(100 %)

Parts involved




item

Tumblinig of engaginggears, shifter sleeves &syncro rings

To elminatescratchyfeeling duringgear shift

Syncro cone1st gear

2684 2620 3823 1 Nil Deleted

Syncro cone2nd gear

2684 2620 3824 1 Nil Deleted

1st gear 3.87ratio *

2684 2620 0146 1 2684 2620 0161 1 Syncro ringhas 3 slots toaccommodatelugs ofintermediatecone


2nd gear 2.22ratio *

2684 2620 0196 1 2684 2620 0164 1 Syncro ringhas 3 slots toaccommodatelugs ofintermediatecone. Alsoun equaldach chamferon syncroring teeth.


Engaging gear1st/2nd *

2684 2620 4611 1 2684 2620 4628 1 Inner collarsymmetricon bothsides. Canbe fitted eitherway.


Shifter sleeve1st/2nd *

2684 2620 4622 1 2684 2620 4629 1 Shifter sleeveOD has onec i r c u l a rgroove on 1stgear side &two circulargrooves on2nd gear side.


Chassis break points indicated here is only for reference.It is possible that few vhicles prior to break point may with modified version. Chassisbreak points for RHD version is applicable for Domestic. Separate break point for Exports RHD version not maitained at Works.

71

GEAR BOX G-76

1st/2nd Gear with Dual Cone Synchroniser

DUAL CONE SYNCHRONISER

1st/2nd Gear with Single Cone Synchroniser

72

GEAR BOX G-76

EXISTING – SINGLE SYNCHROCONE FOR 1ST & 2 ND SPEED

DUAL SYNCHROCONE INTRODUCED – OCT03. (1ST & 2ND SPEED)

73

GEAR BOX G-76

EQUAL DACH CHAMFER ( 2ND & 3RD SPEED GEAR)

UNEQUAL DACH CHAMFER INTRODUCED (OCT-03)

74

GEAR BOX G-76

TUMBLING FOR ENGAGING GEAR & SHIFTER SLEEVEINTRODUCED

75

GE

AR

BO

X G

-76

G76 GEARBOX SPEED GEAR VARIETIES FOR VARIOUS MODELS

Gears may be identified by counting the number of Teeth on each Gear

Safari Diesel 4x2 & 4x4 Safari Petrol 4x2 & 4x4 Telcoline (Diesel & Petrol) 4x2 & 4x4

No of Teeth Part No No of Teeth Part No No of Teeth Part No

1st Gear 33 2684 2620 01 46(With Single Cone Synchro)

2684 2620 01 61(With Double Cone Sunchro)

35 2684 2620 01 95(With Single Cone Synchro)




2nd Gear 42 2685 2620 02 11(With Single Cone Synchro)


41 2685 2620 02 10 (With SingleCone Synchro)

2684 2620 01 64 (With DoubleCone Sunchro)



3rd Gear 38 (only onevariety)

2684 2620 02 12 38 2684 2620 02 12 38 2684 2620 02 12

5th Gear(Overdrive Gear)

25 2684 2620 01 50 25 (0.82 OD Ratio)28 (0.73 OD Ratio)

2684 2620 01 502684 2620 02 07

25 (0.82 OD Ratio) 2684 2620 01 50

Coutershaft 25(2nd Gear) 2684 2630 79 03 26 (2nd gear) 2684 2630 79 05 26 (2nd Gear) 2684 2630 79 05

Double Gear(c/s) 45/39 (onlyone variety)

2684 2630 54 01 2684 2630 54 01

OD Gear (c/s)

2684 2630 54 01

43 2684 2630 54 04 43 (0.82 OD Ratio)54 (0.73 OD Ratio)

2684 2630 54 042684 2630 54 13

43 (0.82 OD Ratio) 2684 2630 54 04

Driveshaft 32 2684 2625 0115(Unequal dach chamfer)

32 2684 2625 0115(Unequal dach chamfer)

32 2684 2625 0115(Unequal dach chamfer)

76

GEAR BOX G-76

1

TRANSFER CASE

TRANSFER CASE

3

TRANSFER CASE

CONTENTS

1. Introduction 5

2. Specifications 7

3. Exploded view and part list 8

4. Lubrication 11

5. Trouble shooting 12

6. Removal and Installation 13

7. Special Tool & Tightening Torque 14

8. Disassembly, Cleaning, Inspection and Assembly 15

9. Electronic Control Unit and Self Diagnosis 33

10. Electric shift assembly 37

5

TRANSFER CASE

INTRODUCTION

1.1 Construction & operation

Divgi-Warner’s 45-54 Transfer case is a two speed, part time electric transfer case. The system consists of

1. Transfer case with motor, speed sensor, and electric clutch

2. Electronic control unit (ECU)

3. Mode selector switch

4. Indicator lights 4H and 4L

5. Harness to connect above parts and power input

Power is received by input shaft, which is coupled with output shaft of transmission gearbox by matchingsplines. There are two outputs, one for rear wheels and one for front wheels.

Position Speed Ratio Operation

N - Neutral position - (Available only in manual shift type transfer case). Output shaft is disconnected from input shaft and no poweris transmitted to wheels

2H - Two high position 1: 1 Only two rear wheels are driven and transfer caseoperates at 1: 1 speed ratio

4H - Four high position 1: 1 All four wheels are driven at 1: 1 speed ratio

4L - Four low position 2.48: 1 All four wheels are driven and transfer case operates at2.48: 1 speed reduction ratio

A planetary gear set is used to provide gearreduction. Power is transferred to front wheel drivethrough a Morse Hi-Vo chain drive. Unit operates inan oil bath. An oil pump is used to provide positivelubrication to planetary gear set and other uppershaft components.

Different drive modes are obtained by rotatingselector switch for selection. This in turn givessignal to Electronic Control Unit (ECU). ECUsenses the conditions and shifts drive into modeselected.

Control system consists of :

1. Control unit housed below driver’s seat orunder dashboard

2. Rotary switch provided for selection ofdifferent modes

l 2H

l 4H

l 4L

3. Indicator lights on dashboard to indicate thestatus (4H-4L)

6

TRANSFER CASE

1.1.1 Identification tag

Identification tag is attached to the transfer case atlocation shown in figure. Manufacturing details arestamped on tag. This information is necessary forordering replacement spare parts.

1.2 Features and benefits

Part-time system Allows driver to select two or four wheel drive operation

Light weight construction Reduces total vehicle’s weight to enhance efficiency

Hi-Vo Chain-driven output Provides quiet four-wheel drive

Upper disconnect to chain Reduces unnecessary parasitic losses in two-wheel drive

Positive displacement oil pump and filter Assures full lubrication while driving or towing. Reducesmaintenance needs.

Helical gearing Delivers quiet low-range operation

Four-wheel drive indicator light switch Indicates four wheel drive for driver's convenience

Selector switch for different modes Simplifies selection of transfer case operating modes

Electromagnetic shift-on-the-fly Provides effortless engagement of four wheel drive at highwayspeeds

1.3 Abbreviations used

2H Two High Position Kmph Kilo meter per hour

2WD Two Wheel Drive lb. Pounds

4H Four High Position N Neutral position

4L Four Low Position Nm Newton meter

4WD Four Wheel Drive oz Ounces

ATF Automatic Transmission Fluid RTV Room Temperature Vulcanizer

Kg Kilo gram ECU Electronic Control Unit

Km Kilo meters V Volts

7

TRANSFER CASE

2.1 Transfer Case 45-54 technical specifications :

Configuration Part time, Single Off set

Rear Output Configuration Fixed Yoke

Front Output Configuration Fixed Yoke

Input Configuration Female Spline

Drop Angle 40 degrees

Offset hand Right hand

High Range Ratio 1 : 1

Low Range Ratio 2.48 : 1

Lubrication System Forced lubrication by Gerotor pump

Fluid Type Multigrade oil conforming to ATF toGeneral Motors, Type A, Suffix Aspecifications.

Housing Material Aluminium

Dry Weight in kg 29

Oil Capacity in liter 1.2

Shift Pattern 2H - 4H- 4L

Shift Control Selector switch

4WH Shift-on-the-fly Optional

SPECIFICATIONS - TRANSFER CASE 45-54

8

TRANSFER CASE

EXPLODED VIEW OF TRANSFER CASE

Figure A . 1 : Exploded view with part codes

9

TRANSFER CASE

Index Part Name QuantityNo.

1. Nut 1

2. Washer 1

3. Seal 1

4. Rear Yoke 1

5. Plug, Pipe 2

6. Bolt, Hex Head 1

8. Bolt, Hex Head 3

9. Bracket, Sensor and Harness 1

10. Sensor Assembly 1

13. Motor Assembly 1

14. Bolt, Hex Head 9

15. Clip, Wiring Harness 1

16. Tag Identification 1

17. Cover Assembly Transfer Case 1

18. Seal Oil 1

19. Bearing Sleeve 1

20. Nut, Hex 3

21. Coil Assembly, Clutch 1

22. Ring, Snap 1

23. Bearing Annular 1

24. Bearing, Needle 1

25. Cover, Transfer Case 1

26. Magnet 1

27. Gear, Speed (8T) 1

28. Seal, Oil 1

29. Spring Return 1

31. Housing, Clutch 1

33. Lockup Assembly 2W-4W 1

34. Ring, Snap 1

35. Hub, Lockup 1


36. Spring, Sleeve Return 1

37. Collar, Lockup 1

38. Shaft, Rail 1

39. Fork, Lockup 1

40. Ring Snap 1

41. Spacer 1

42. Sprocket, Drive 1

43. Sprocket, Driven 1

44. Chain, Drive 1

45. Shaft and Pump Assembly 1

49. Clamp, hose 1

50. Coupling Hose 1

51. Gerotor Pump 1

54. Facing, Lockup fork 2

55. Assy. Shaft, Output 1

56. Strainer, Oil 1

57. Hub, Reduction 1

58. Facing Reduction Fork 2

59. Fork Assembly Reduction Shift 1

60. Pin Roller and Retainer Assembly 1

65. Nut 1

66. Washer 1

67. Seal, Oil 1

68. Yoke Assembly DC 1

69. Deflector Dust 1

70. Yoke DC 1

71. Shaft, Front Output 1

72. Stud 5

73. Bolt, Hex Stud. 6

74. Adapter Assembly, Front 1

10

TRANSFER CASE


75. Ring, Snap 1

76. Seal Oil 1

77. Pin, Spirol 1

78. Adapter, Front 1

79. Ring, Snap 1

80. Bearing Annular 1

81. Shaft Assembly, Input 1

82. Bearing, Bush 1

83. Bearing, Needle 1

84. Shaft, Input 1

85. Washer, Thrust 1

86. Carrier Assembly, (Complete) 1

87. Snap Ring 1

88. Plate, Thrust. 1

89. Gear, Sun 1

90. Carrier Assembly, Planet 1

91. Assembly Speedo Gear & Shaft 1

92. Gear Speedo Driven 1

93. Shaft Speedo Driven 1

94. Seal, Speedo 1

95. “O” Ring 1

96. Body, Speedo 1

97. Bolt 1

98. Breather Assembly 1

100. Cam, Electric Shift 1

101. Spring, Torsion 1

102. Spacer 1

103. Shaft, Shift 1

105. Case Assembly, Transfer 1

106. Seal, Oil 1


107. Ring Snap 1

108. Bearing, Annular 1

109. Pin, Dowel 2

111. Case, Transfer 1

112. Sealing Compound 1

113. Wire Connector, Electrical Coil 1

114. Clip Connector, Electrical Coil 1

115. ECU Module 1

116. Bracket, Relay Mounting 1

117. Connector, Three Terminal 1

118. Connector, Locking Clip 1

11

TRANSFER CASE

Precautions

l Before checking or removing oil, warming up the transfer case is necessary. This should be doneby driving the vehicle for a short distance.

l Do not use an impact wrench to open or tighten the drain and oil level plugs. This may damagethreads in transfer case housing.

3.1 Checking oil level

l Clean oil level plug and surrounding area

l Remove oil level plug and check whether oilis dripping out

l If oil is not dripping out, oil level must bebelow the required level. Add specified oil tobring it to level till it starts dripping out

l Tighten oil level plug

3.2 Changing

l Clean oil level plug, drain plug and surroundingarea

l Place a container to collect oil, under thetransfer case

l Remove drain plug

l Remove oil level plug

l Let the oil drain out

l Tighten drain plug

l Fill new oil through oil level plug hole, till itbegins to drip out

l Tighten oil level plug

3.3 Lubrication Schedule

Frequency Procedure

Every 10,000 km Check transfer case oil level,if required, top up

Yearly or after every 40,000 km Change transfer case oil with the specified lubricantwhichever occurs earlier

NOTE :l Use Torque wrench to tighten threaded partsl Torque Values are specified in Table 6.1, on page 27

Figure 3.1 : Drain and Fluid level plugs

LUBRICATION

12

TRANSFER CASE

4.1 Troubleshooting

Malfunctions of transfer case due to system elements are diagnosed by ECU and indication is given byflashing of both 4H and 4L indicator lights. Refer self diagnosis to identify the cause detected by ECU.

Problem Possible causes Remedy

Electric shift problems

No front wheel drive whenshifted to 4H or 4L

Noise in 4WD operation

Transfer case oil leakage

Faulty or damaged ECU, speedsensor, clutch or internal wiring

Damaged or worn shift cam, hub, forkand rail shaft

Broken drive chain

Low oil level/contaminated oil

Loosened bolts or mounting parts

Noisy transfer case bearings/parts

Worn or damaged sprockets of drivechain

Incorrect tire pressure

Cracked transfer case

Leakage from other parts

Breather clogging

Oil level higher than required orimproper specification of oil beingused

Loosened sealing bolts

Improper specification of sealant orimproperly applied sealant

Worn or damaged oil seal

Refer to self diagnosis

Overhaul and check for wear and damage.Replace if necessary

Check internal parts and replace ifnecessary

Top up / change oil

Re-tighten as specified

Disassemble bearings and parts andcheck for wear or damage. Replace ifnecessaryCheck for wear and damage includingspeedometer gear and replace ifnecessary

Disassemble and check for wear anddamage. Replace if necessary

Adjust tire pressure

Replace the case

Clean case and parts and check forleakage

Remove breather with breather adapterand clean it. Replace if necessary

Use specified oil. Adjust oil level

Re-tighten

Use specified sealant and re-tighten

Replace oil seal

TROUBLESHOOTING

13

TRANSFER CASE

5.1 Removal of transfer case 45-54

1. Disconnect negative terminal from battery

2. Lift up vehicle

3. Remove transfer case drain and level plugs.Drain oil and reinstall plugs

4. Remove breather assembly

5. Disconnect speedometer cable connector,motor connector and sensor connector

6. Support transfer case with jack anddisconnect front and rear propeller shafts fromtransfer case

8. Remove transfer case by removing mountingstud nuts attaching transfer case totransmission

5.2 Installation of transfer case 45-54

Follow procedure in reverse order for installation

REMOVAL AND INSTALLATION

Figure 5.1 : Transfer Case installation

14

TRANSFER CASE


LEVEL - I SERVICE (At Dealer Level)

Sr. No. Tool Description Telco Part No.

1. Repair Fixture I 2704 5890 2807 N

2. Yoke holder 2704 5890 2802 N

3. Oil seal fitting tool (Motor) 2704 5890 2804 N

4. Seal driver 2704 5890 2801 N

LEVEL - II SERVICE (At Distributor Level)

Sr. No. Tool Description Telco Part No.

1. Repair Fixture II 2704 5890 2808 N

2. Yoke holder 2704 5890 2802 N

3. Oil seal fitting tool (Motor) 2704 5890 2804 N

4. Seal driver 2704 5890 2801 N

5. NRB removing fixture (input shaft) 2704 5890 2805 N

6. Needle bearing puller (Cover) 2704 5890 2809 N

7. Snap ring pliers (Lower output shaft) 2704 5890 2810 N

8. Snap rings pliers (Adapter) 2704 5890 2803 N

9. Drift for ball bearing 2704 5890 2811 N

TORQUE TABLE

Level & Drain Plug : (20-30 ft.lb) 2.8 - 4.2 kgm.

Yoke Nut Front : (250-275 ft.lb) 34 - 38 kgm.

Case Bolts : (20-30 ft.lb) 2.8 - 4.2 kgm.

Breather Adapter : (6-14 ft.lb) 0.8 - 1.9 kgcm.

Motor Mount : (6-8 ft.lb) 0.8 - 1.1 kgcm.

Motor Bracket : (6-8 ft.lb) 0.8 - 1.1 kgcm.

Clutch Coil Nut : (6-8 ft.lb) 0.8 - 1.1 kgcm.

Rear Output Yoke Nut : (250-275 ft.lb) 34 - 38 kgm

15

TRANSFER CASE

External electric shift parts

1. Remove bolt/washer holding motor assembly.

2. Remove 3 bolts holding sensor and harnessbracket.

3. Remove sensor assembly and remove O-ringfrom speed sensor.

4. Remove motor assembly.

DISASSEMBLY, INSPECTION, CLEANING AND ASSEMBLY

6.1 Disassembling

End Yoke

1. Holding end yoke by yoke holding tool, removenut and washer and then remove end yoke

2. Remove the two plugs from the cover

3. Remove bolt and remove speedo assembly

Figure 6.1 : Yoke Group

Figure 6.2 : External Electrical Shift Parts

16

TRANSFER CASE

Cover assembly

1. Remove 9 bolts holding transfer case cover tohousing, wiring harness clip and identificationtag.

2. Pry and disconnect sealant bond of cover andtransfer case in such a way that metal surfaceof cover & housing is not damaged.

3. Remove oil seal, bearing, 3 nuts holdingclutch coil assembly of electric shift unit.

4. Remove snap ring and pull out ball bearingfrom cover. Remove speedo drive gear.

5. Pull out needle bearing from cover.

6. Pull out oil seal from cover

7. Remove magnet from its slot in the case.

4. Remove return spring from rail shaft

5. Clean and remove sealant from cover andcase. Be careful not to damage metal surface.

Note : Identification tag has information relatedto ordering of spare parts. Preserve it carefully.

Figure 6.3 : Cover Assembly

17

TRANSFER CASE

Drive chain

1. Remove snap ring and spacer from the outputshaft (front)

2. Remove drive chain, driven sprocket and drivesprocket from output shaft (front)

3. Separate chain from sprocket during removal.

Lock up shift parts

1. Remove snap ring and clutch housingassembly.

2. Separate 2WD and 4WD lock up assemblyand lockup fork from rail shaft

3. Remove snap ring, lock up hub and returnspring from lock up collar.

Figure 6.4 : Lock up Shift parts (Electrical shift)

Figure 6.5 Chain Drive

18

TRANSFER CASE

Gerotor pump assembly

1. Loosen hose clamp and remove hosecoupling from pump housing.

2. Remove hose clamp, hose coupling andstrainer.

3. Take output shaft (rear) with gerotor pump.

4. Separate pump and output shaft.

Reduction shift parts

1. Remove reduction hub and reduction forkassembly from case.

2. Remove shift fork facings (2 nos.) from shiftfork.

Figure 6.6 Gerotor Pump

Figure 6.7: Reduction Shift Parts

19

TRANSFER CASE

Front output assembly

1. Holding end yoke with yoke holder, remove nutand washer. Remove end yoke and seal.

2. Separate end yoke and deflector. Removeoutput shaft

Adapter Input and carrier gear

1. Remove breather and adapter

2. Remove six bolts

3. Remove adapter by separating adapter sealerbond (pry front adapter, take care not todamage the adapter or case).

4. Remove adapter assembly, input shaftassembly and carrier gear assembly.

5. Remove snap ring and oil seal from frontadapter.

6. After removing snap ring, pull out bearing andthrust washer from input shaft assembly andseparate input shaft assembly from carriergroup assembly.

7. Remove needle bearing and sleeve bearingfrom input shaft assembly.

8. Remove retainer ring, thrust plate and sungear from planet carrier assembly. Do notdisassemble planet carrier assembly.

Figure 6.8 : Front out put shaft Assembly

Figure 6.9 : Adapter, input shaft and gear carrier group

20

TRANSFER CASE

Electric shift cam parts

1. Remove electric cam shift parts from caseassembly.

2. Separate electric shift cam from shift shaft.

3. Holding shift shaft in a soft jaw, removetorsion spring and spacer from shift shaftusing a 1/2” screw driver.

Transfer case assembly

1. Remove oil seal.

2. Remove retaining ring and ball bearing.

3. Remove the pin from transfer case.(Do not remove Ring Gear)

Figure 6.10 : Electric shift cam part

Figure 6.11 : Transfer Case

21

TRANSFER CASE

6.2 Cleaning

Note : Before cleaning, check magnet for presenceof metal particles which indicate internalchipping of transfer case.

1. Using a cleaning solvent, clean old oil and dirtdeposits.

2. After cleaning, dry parts with low pressure (20psi maximum) compressed air.

3. Lubricate ball bearings and needle bearing withATF oil. Protect lubricated bearings from dust.

6.3 Inspection

1. Visually check all parts for damage.

2. Referring to normal gear tooth face,specifically inspect uneven wear and chips ofgear tooth. Replace if necessary.

Note : Always replace hose couplings, O-rings andoil seals with new parts.

Figure 6.12 : Normal Gear tooth tool marks

Figure 6.13 : Gear tooth contact pattern

22

TRANSFER CASE

6.3.1 Inspection terms

Burr Local rise of material forming protruding sharp angle

Chip An area from which a small fragment has broken off or cut

Crack Surface break of line nature indicating partial or complete separation of material.

Excessive wear Heavy or obvious wear beyond expectations, considering conditions of operation.

Indentation Displacement of material caused by localized heavy contact

Galling Breakdown of metal surfaces because of excessive friction between parts. Particlesof the soft material are torn loose and welded to the harder material.

Nick Local break or notch. Usually displacement of material rather than loss.

Scoring Tear or break in metal surface from contact under pressure. May show discolorationcaused because of heat generated by friction

Step wear Heavy wear that produces step that can be seen or felt between adjacent contactand non-contact surfaces.

Uneven wear Condition of localized, unevenly distributed wear. Includes hollows, shiny spots,uneven polish and other visual conditions.

23

TRANSFER CASE

6.4 Assembling

General information

l Do not use hammer to drive in oil seal andbearing. Use special tools for assembly of oilseals and bearings (described in Appendix B)

l Torque values are specified in Table 6.1 onpage 27.

l Lubricate bearings, oil seals, O rings,bushings and matching metal parts beforeassembly.

Transfer case

1. Insert new dowel pins (2 nos.) in transfercase.

2. Insert ball bearing into the case and installretaining ring.

3. Install new oil seal, by pressing it into case.

4. Make sure that all parts are correctly andfirmly installed into case.

Figure 6.14 : Transfer case Assembly

Figure 6.15 : Installing parts in Transfer case

24

TRANSFER CASE

Electric shift cam parts

1. Insert spacer into torsion spring.

2. Insert end of the shift shaft into spacer.

3. Slide torsion spring and spacer to the left ofshift shaft and position end of first spring tofix on drive tang (figure 6.17).

4. Push the end of second spring to right and fixit on drive tang (figure 6.18).

5. Push torsion spring and spacer back togetherand fix them (figure 6.19).

6. Slide electric shift cam onto shift shaft.

7. Install electric shift cam assembly intotransfer case after installation of shift fork.

Figure 6.16 : Electric shift cam parts

Figure 6.17 : Installing first spring end

Figure 6.18 Installing second spring endFigure 6.19 : Complete Spring assembly

25

TRANSFER CASE

1. Place planet carrier assembly on a workbench such that retaining ring’s mountinggroove faces upward.

2. Install sun gear with the hub end up intoplanet carrier assembly. Rotate sun gear tomake sure that gears are fully meshed.

3. Align tabs and install thrust plate into planetcarrier assembly.

4. Install retaining ring to planet carrier assembly.

5. Press needle bearing and bearing sleeve intoinput shaft assembly (figure 6.21). Use newbearing sleeve.

6. Install planet carrier assembly onto input shaftand install thrust washer. Press the bearingover input shaft.

7. Install retaining ring.

8. Press spirol pin into front adapter.

Adapter, input shaft and carrier

Figure 6.20 : Adapter, input shaft and gear carrier group

Figure 6.21 Input shaft assembly

26

TRANSFER CASE

9. Press oil seal into front adapter (figure 6.22).

10. Install front adapter assembly. Make sure thatsnap ring is correctly installed into the groove.

11. Position input shaft assembly over front coverand engage into bearing groove by expandingthe ends of snap ring

12. Apply 1.6 mm bead of sealant on mountingface for transfer case and tighten six bolts.

13. Install breather with adapter.

Front Output shaft

1. Press the deflector onto yoke (figure 6.23)

2. Position output shaft in transfer case andinstall end yoke assembly, seal, washer andnut.

3. Holding end yoke, tighten the nut.

Figure 6.22 : Front adapter assembly

Figure 6.23 : Front output shaft assembly

27

TRANSFER CASE

Reduction shift parts

1. Install new pin, roller into reduction shift fork.

2. Press pin, roller into reduction shift fork bore.Ensure that cam roller turns freely

3. Install fork facings (2 nos.) on reduction shiftfork assembly.

4. Install reduction shift fork onto reduction hubin transfer case.

5. Install output shaft spline into reduction huband engage output shaft end with input shaftbearing.

Gerotor pump assembly

1. Fit the pump pin in output shaft.

2. Slide pump assembly on output shaft overpump pin.

3. Slip hose clamp over free end of hosecoupling with strainer and push onto hosebarb on pump and tighten.

Figure 6.24 : Reduction shift parts

Figure 6.25 : Gerotor pump assembly

28

TRANSFER CASE

Drive Chain

1. Position drive sprocket to rear output shaftend and driven sprocket to front output shaftend.

2. Install drive chain onto sprocket.

3. Holding each sprocket with drive chain tightand parallel with transfer case, install the drivechain assembly to output shaft.

4. Rotate driven sprocket slightly to engagesplines on front output shaft.

5. Install spacer to front output shaft and insertsnap ring into the groove over spacer.

Figure 6.26 : Chain Drive

29

TRANSFER CASE

Lockup shift

1. Install lockup hub and return spring to thelock up collar and insert snap ring.

2. Install rail shaft through reduction shift forkassembly and into the blind holes in case.

3. Engage lockup fork in 2WD-4WD groove andcheck operation.

4. Install electric shaft cam and assemble clutchhousing as follows (figure 6.28).

l Rotate shift cam assembly to right sothat the end of torsion spring contactswith reduction shift fork inside.

l Holding rail shaft, lift up fork assemblyslightly. Adjust electric shift camassembly so that the roller on reductionshift cam assembly is in groove in shiftcam and button on lockup fork is on camend.

l Install clutch housing assembly.

Figure 6.27 : Lockup shift parts

Figure 6.28 : Electric shift cam installation

30

TRANSFER CASE

Cover

1. Position the cover with open end facing up onthe table.

2. Position needle bearing with identificationmark up and press into the cover until upperend of bearing is 40.47 - 40.97 mm belowcover face.

3. Press ball bearing into cover and install snapring.

4. Install remaining parts as follows

l Install four O-rings on stud bolts ofclutch coil assembly.

l Install clutch coil assembly inside thecover and tighten three nuts.

l Install bearing and motor bearing into thecover. Figure 6.29 : Cover assembly

Figure 6.30 : Cover installation

31

TRANSFER CASE

Cover assembly

1. Install return spring over rail shaft in transfercase.

2. Insert magnet into transfer case slot.

3. Apply 1.6 mm bead of Loctite RTV598 totransfer case mounting surface. Forinstallation of cover, align transfer case withcover. Do not use excessive force.

4. Install the cover into transfer case as follows:

l Align cover holes with transfer casedowel pins.

l Align cover bearings with output shafts.

l Align the cover blind hole with rail shaftand make sure that return spring is notcocked.

5. Tighten nine bolts positioning identification tagand wiring clip.

6. Install speedo gear over output shaft spline incover assembly.

7. Press new oil seal into cover assembly.

Figure 6.31 : parts to be aligned with the cover

Figure 6.32 : Motor assembly alignment

32

TRANSFER CASE

External electric shift

1. Align motor with shift shaft and position motorassembly onto the cover (figure 6.32).

2. Install the motor to shift shaft and contactcover. Rotate the motor clockwise direction tocheck correct engagement.

3. Insert O-ring on speed sensor and installspeed sensor assembly to cover.

4. Install the bracket to motor assembly andtighten three bolts (figure 6.33).

End yoke

1. Install two plugs to cover (figure 6.34).

2. Install end yoke, seal and washer.

3. Holding end yoke tighten nut.

Note : Apply Locitte 262 to nut before installation.

Figure 6.33 : External electric shift parts

Figure 6.34 : Yoke Group

33

TRANSFER CASE

7. 1 Description

Electronic Control Unit (ECU) is located under co-driver’s seat or under dashboard. Driver operates aselector switch to shift the drive from two-wheeldrive to four-wheel drive (and vice versa). Shiftingduring driving is possible only between 2H & 4Hmodes.

Interconnections between ECU and other systemblocks are shown in Figure 7.1

ELECTRONIC CONTROL UNIT

Figure 7.1 : wiring schematic

34

TRANSFER CASE

7.2 Operating transfer case:

1. Shifting from 2WD to 4WD

l Shift selector switch mode from 2H to4H. 4WD HI indicator light will turn On

l Shifting is possible during driving

2. Shifting from 4WD to 2WD

l Shift selector switch mode from 4H to2H. 4WD HI indicator light will turn Off

l Shifting is possible during driving

3. Shifting from 4H to 4L

l Stop the vehicle

l Apply clutch

l Shift selector switch mode from 4H to4L. 4WD LO indicator light will turn On

4. Shifting from 4L to 4H

l Stop the vehicle

l Apply clutch

l Shift selector switch mode from 4L to4H. 4WD HI indicator light will turn On

Note : In case of malfunctioning in shifting, 4WDHI and 4WD LO indicator lights will flash.

Important Note :

1. Do not march the vehicle till 4H/4L indicatorlamp stops blinking.

2. Disengage the hub lock by shifting the vehiclein 2H mode for servicing. Make sure that ehehand brake is 'Engaged'

Caution :

Do not engage 4H/4L on tarmac roads / hardsurfaces like concrete road or floors.

Auto Hub lock functioning :

a) Locks automatically after shifting to 4H/4L.

b) To unlock / free wheeling (From 4H/4L to 2H)reverse the vehicle (if in forward gear) ORforward the vehicle (if in reverse gear).

35

TRANSFER CASE

7. 3 Self diagnosis of ECU:

ECU detects transfer case system malfunctionsand indicates through flashing indictor lights.Operator will be alerted of fault condition bycontinuous illumination of both 4WD HI and 4WDLO lights when ignition is On.

A service connector is provided to indicate faultcodes in binary. Connect one end to the pin holenumber 22 in ECU connector, and other end toignition switch. Flashing of indicator light will showdefective code (as illustrated in the table). Identifymalfunctioning part and replace it.

L1 L2 L3 Binary code Decimal equivalent Fault with

Off Off On 001 1 ECU Module

Off On Off 010 2 Shift Motor

Off On On 011 3 Synchronizer Clutch

On Off Off 100 4 Speed Sensor

On On Off 110 6 Selector switch

On On On 111 7 Motor Position Switch

If only one part is malfunctioning, indicator light willdisplay defective code three times continuously. Ifmore than two parts are malfunctioning, firstmalfunctioning part will be displayed three timesand then other malfunctioning parts will bedisplayed.

After repair, clear the fault stored in memory.Ground the service connector and keep ignition ‘On’for five seconds continuously to erase defectivecode.

Note :

l Before replacing malfunctioning parts asindicated by system, check wires andconnectors for proper condition.

l Use only 12v 3-watt bulb for diagnosticpurpose.

36

TRANSFER CASE

Diagnostic Table

Connect a service connector as described earlier.Turn ignition switch On. 4WD CHECK indicator willturn On for 0.6 seconds and turn Off for 3 seconds.Then it will display a defective code 3 timescontinuously.

Figure 7.2 : Defect code diagram

37

TRANSFER CASE

Electric shift assembly is externally attached totransfer case. Disassembling and assemblingprocedure is covered in Chapter 6. This chapterexplains operation of these parts.

8.1 Electric shift assembly parts

Electric shift assembly consists of

1. Activating Motor

2. Sensor

3. Speed Sensor

4. ECU

5. Selector Switch

6. Magnetic Synchronizer Clutch

8.2 Functioning of electric shift assembly

Motor : It is used to turn the shift shaft. Shaftrotates in steps.

Position Sensor : It senses the position of shaftand thus the operating mode of transfer case.

Speed sensor : It is a rotary encoder embeddedin transfer case. It is not a user serviceable part.In case of any problem, entire assembly has to bereplaced.

ECU : Refer page 33 for details.

Selector Switch : To shift transfer case in differentmodes.

Magnetic Synchronizer Clutch : Electromagneticsub-component of the transfer case, controlled byECU and used for shifts from 2H to 4H.

ELECTRIC SHIFT ASSEMBLY

1

ACCELERATOR /IDLING ADJUSTER CABLE

ACCELERATOR CABLE &

IDLING ADJUSTER CABLE

3


FIP lever is operated by accelerator cable. One endof cable is connected to accelerator pedal & otherend to FIP lever.

Engine speed is controlled by travel of FIP lever, whichis actuated by accelerator pedal through cable.

Engine idling speed, if required, can also be adjustedby operating idling speed adjuster knob. This provisionis given to increase fuel flow to the system, which isrequired for cold start conditions.

This mechanism is operated by a cable connectingidling adjuster knob & FIP lever.

If this device is used, adjuster knob has to be broughtback to normal idling position after engine warms up.

Introduction

5


Fig. 1

Description

1 Assy. Accelerator Cable

2 Assy. Accelerator Pedal Rod Complete - LHD

2A Assy. Accelerator Pedal Rod Complete - RHD

3 Rubber Stopper

4 Spring (for Accelerator Rod)

5 Spacer

6 Split Pin 3.2 x 16 IS549 SS8451-8C

7 Assy. Idling adjuster cable with bracket

8 Assy Pedal Plate

9 Spring

10 Clevis Pin (Acc. Control)

10A Split Pin 1.6 x 10

11 Rubber Cover

11A Packing Foam

11B Packing Foam

12 Ball Pin C10

13 Lock Plate

14 Ball End Assy B10

15 Locking Ring 10

6


INSTALLATION OF ACCELERATOR CABLE

1. Remove hex nut & sealing washer fromaccelerator cable pedal end.

2. Insert accelerator cable pedal end inside fire wallhole.

3. Fasten hex nut & sealing washer removed earlier.

4. Insert inner cable end in accelerator pedal.(Refer fig. 2 & 3).

5. Loosen the nut from the threaded end of cable.Engage threaded end of cable in throttle bodybracket. Tighten ball end assembly (14) on FIPend of accelerator cable. Insert ball end assemblyin FIP lever ball pin (12). Lock the ball endassembly with locking ring. (Refer fig 1 & 5)

Fig. 2 Fig. 3

LHD RHD

42± 2

Hex Nut

Fig. 4

��

7


6. Ensure dimensions 67 ± 3 for RHD and 42 ± 2for LHD. Ensure tightness in inner cable byadjusting the nuts on threaded end of the cable.

7. Ensure that when accelerator pedal is fullypressed, full travel of throttle lever is achieved.

REMOVAL OF ACCELERATOR CABLE

Removal of accelerator cable is in reverse order ofinstallation.

INSTALLATION OF IDLING ADJUSTER CABLE

1. Assemble idling adjuster cable & bracketassembly on BIW bracket.

2. Rotate idle control knob anticlockwise completely(as seen by driver) and connect the cable to thepedal. Tighten the hex nut on knob end such thatthere is no slackness on idling adjuster cable.(Refer fig. 4)

REMOVAL OF IDLING ADJUSTER CABLE

Removal of idling adjuster cable is in reverse order ofinstallation.

Fig. 5

��

��

1

SUSPENSION

SUSPENSION(FACELIFT VERSION)

3

SUSPENSION

Independent suspension arrangement has been used

at front. In this design, each wheel is a separately

suspended unit connected to chassis in such a manner

that rise and fall of one wheel does not affect the

other directly.

As a result, each wheel has the ability to maintain a

level position regardless of the influences on other

front wheel.

In addition independent front suspension improves the

ride quality and handling of the vehicle.

Facelift version :

Torsion bar spring is used in front suspension with

wide upper and lower wishbones. Torsion bar preload

can be adjusted by adjusting screws provided at rear

end of torsion bar. Wheel alignment is by means of

shims provided on upper wishbone.

Parabolic leaf spring, underslung type is provided at

rear. Axle is connected to leaf spring at the bottom

through ‘U’ bolts.

Telescopic shock absorbers at front and rear, antiroll

bar in front ensure vehicle stability & smooth ride.

INTRODUCTION :

5

SUSPENSION

CONTENTS


I. FRONT INDEPENDENT SUSPENSION

1. Constructional details 7

2. Specifications 7

3. Special tools 7

4. Removal/dismantling procedure

A. Removal of front wheels 9

B. Removal of front antiroll bar 9

C. Removal of front shock absorber 9

D. Removal of torsion bar 11

E. Removal/dismantling of upper wishbone 11

F. Removal/dismantling of lower wishbone 13

5. Inspection of components 13

6. Assembly/installation procedure

A. Assembly/installation of lower wishbone 13

B. Assembly/installation of upper wishbone 15

C. Installation of front shock absorber 15

D. Installation of front antiroll bar 17

E. Installation of front wheels 17

F. Installation of torsion bar 17

7. Wheel alignment

A. Camber angle adjustment 19

B. Castor angle adjustment 19

C. Toe-in adjustment 19

D. Wheel lock angle adjustment 20

II. REAR SUSPENSION


2. Special tools 21

3. Tightening Torques 21

4. Construction Details 22

5. Removal of Rear Shock Absorber 23

6. Installation of Rear Shock Absorbers 23

7. Removal of Rear Spring Assembly 24

8. Inspection 24

9. Installation of Rear Spring Assembly 25

6

SU

SP

EN

SIO

NFig. 1 - Front independent suspension (Torsion bar type)

VEHICLE FRONT

UPPER WISHBONE

SHOCK ABSORBER

TORSION BAR

ANTIROLL BAR

LOWER WISHBONE

7

SUSPENSION

I. FRONT INDEPENDENT SUSPENSION

1. CONSTRUCTIONAL DETAILS (Fig.1)

In this arrangement each wheel has a separatesuspension unit. Wheels are connected to chassisin such a manner that the rise and fall of onewheel has no direct effect on the other.

As a result, each wheel has the ability to maintaina level position regardless of the action of otherwheel. In addition, independent front suspensionimproves the ride and handling qualities of thevehicle.

Open end of upper wishbone is mounted onchassis long member through a spindle andpivoted bushes. Closed end of upper wishboneis connected to top of stub axle by a ball joint.

Lower wishbone is pivoted to chassis frame.

Front end of torsion bar is connected to lowerwishbone with bracket at rear pivot pin and rearend to torsion bar adjustment lever connected atcross member.

Ball joint on lower wishbone is connected tobottom end of stub axle.

Antiroll bar middle portion is connected tobrackets on RH and LH long member with bearingblocks (rubber) and clamps. Antiroll bar ends areconnected to brackets on lower wishbones withbolts, cups, sleeves and rubber bushes.

As the wheel moves up and down, the two controlarms (upper wishbone and lower wishbone) pivotup and down , as torsional torque of preloadedtorsion bar increased or reduces. Thus torsionbar gives springing actions.

The shock absorber located between frame andlower wishbone, dampens the springingoscillations.

2A. TECHNICAL SPECIFICATIONS

Type : Double wishbone type with torsion barsprings, double acting hydraulic shock absorberand antiroll bar.

2B. REPAIR/ADJUSTMENT DATA

Shock absorber data

Extended length 370 ± 4 mm(eye centre to middle of cups)

Collapsed length 264 ± 3 mm(eye centre to middle of cups)

Stroke 106 ± 7 mm

Front wheel alignment data

Camber angle 00 ± 30'

Castor angle 30 ± 30'

Toe-in 2 - 5 mm

Wheel lock angle (outer) 260 - 10

LH/RH variation in castor 45'

2C. LUBRICANTS

Antiroll bar contact surface in bearing block tobe lubricated with Silicon Molycote 33 (medium)grease.

Torsion bar splines to be lubricated with 3%MOS2 grease (Servo molex grease)

2D. TIGHTENING TORQUES (mkg.)

Top ball joint 12-15(at upper wishbone castle nut)

Bottom ball joint 12-15(at lower wishbone castle nut)

Upper wishbone spindle attachment 18to chassis, M14 x 1.5 bolt/nut

M12 Screws connecting washer, 8-9pivot bus to spindle

Lower wishbone mounting pin nyloc nut 14-16

Bolts connecting top ball joint to 3upper/lower wishbone

Antiroll bar bearing block clamp 5mounting bolts

Wheel nuts 12 to 15

Bolts connecting lower ball jointto lower wish boneM10 Screws 6-7M12 Bolts 10

3. SPECIALTOOLS

Description Part Number

Adaptor for lower wishbone 2699 5890 41 01mounting

Adaptor for upper wishbone 2699 5890 41 02mounting

Mandrel for installation of 2654 5890 32 01clip ring on ball joint.

Puller for removal of upper & 2654 5890 32 03lower ball joints

8

SUSPENSION

Fig. 2 - Removal of antiroll bar

Fig. 3 - Removal of shock absorber

9

SUSPENSION

FRONT JACKING

POINT

4. REMOVAL & DISMANTLING PROCEDURE

4A. REMOVAL OF FRONTWHEELS

● Place wheel chocks on both sides of rear wheelsto secure the vehicle against any movement.

● Loosen front wheel nuts.

● Keep the jack below long member, behind frontwheel and jack up (Fig.4). Support the frame longmember behind front wheel with suitable support.

● Similarly jack up other side and support longmember.

● Unscrew and remove wheel nuts.

● Remove front wheels.

48. REMOVAL OF ANTIROLL BAR (Fig. 2)

● Unscrew and remove nuts holding antiroll bar tothe bracket on lower wishbone and remove bolt,cups, sleeve and rubber bushes (Fig.5).

● Unscrew and remove hex. screws holding antirollbar bearing block (rubber) and lamp with thebracket on chassis frame long member.

● Remove bearing block (rubber) and clamp fromantiroll bar assembly.

● Take out antiroll bar.

4C. REMOVAL OF SHOCK ABSORBER (Fig.3)

● Unscrew and remove nyloc nut holding shockabsorber top (Fig.6). Remove spacer and bush.

● Unscrew and remove bolt connecting the shockabsorber bottom with mounting bracket on lowerwishbone.

● Compress the shock absorber and remove it.

Fig. 4 - Jacking the wheel

Fig. 6 - Removal of shock absorber

Fig. 5 - Antiroll bar mounting on lower wishbone

10

SUSPENSION

Fig. 8 - Removal of upper wishbone and lower wishbone

Fig. 7 - Removal of torsion bar

MOUNTING BRACKETON LOWER WISHBONE

TORSION BARFRONT END

ANCHOR BOLT

TORSION BARREAR END

ADJUSTING NUTLOCK NUT

UPPER WISHBONE

ANTIROLLBAR

TORSIONBAR

SHOCKABSORBER

LOWERWISHBONE

11

SUSPENSION

Fig. 9 - Removal of torsion bar

Fig. 10 - Removal of upper wishbone

Fig. 11 - Dismantling of upper wishbone

4D. REMOVAL OF TORSION BAR (Fig.7)Caution :

Torsional load is applied on torsion bar bytightening the lever adjusting nut and lock nut.

Front suspension is working on torsional springingaction of torsion bar.

Before removing torsion bar or upper wishboneor lower wishbone or ball joints of stub axlemounting, torsion bar load must be released fullyby loosening lever adjusting lock nut and nut toavoid flyout of components and thereby causingany injury.

● Loosen torsion bar lever adjusting lock nut andnut till torsion bar load is fully released.(Fig.9)Remove lock nut, nut bolt and spherical washer.

● Pull out torsion bar from mounting bracket onlower wishbone. Remove lever.

4E. REMOVAL/DISMANTLING OF UPPERWISHBONE (Fig.8)

● Take out the split pin locking castle nut of topball joint of stub axle. Hold steering wheel. Unscrewand remove castle nut.

● Push out ball joint from the stub axle using specialtool Pt. No. 2654 5890 32 01. Properly supportstub axle.

● Unscrew and remove 2 screws (Fig. 10)connecting spindle on top wishbone to bracketon chassis frame, using adaptor (Pt. No. 26995890 4102).

● Take out top wish bone complete with ball joint,spindle etc. Collect the shims located betweenspindle and bracket.

● Unscrew and remove 4 screws holding ball jointassembly to top wishbone. Take out ball jointassembly. (Fig. 11)

● Unscrew and remove the 4 screws connectingtop wishbone and spindle. Remove washers.

● Press out the spindle with one pivot bush fromtop wishbone assembly in a press using suitablebrass punch/handle. Press out the other pivotbush also from top wishbone.

UPPER WISHBONE

SPINDLE

BALL JOINT

HEX SCREW

12

SUSPENSION

Fig. 13 - Installation of lower wishbone

Fig. 12 - Assembly of lower wishbone

PIVOT BUSH

TORSION BAR MOUNTINGBRACKETHEX. SCREW M12 x 1.5 x 45

BRIGHT WASHER 13SPRING WASHER B 12HEX. NUT M 12 x 1.5TORQUE 10 Kg-m

HEX. SCREW M10 x 40BRIGHT WASHER 10.5SPRING WASHER B 10

HEX. NUT M 10TORQUE 6-7 Kg-m

LOWER BALL JOINT

HEX. SCREW M12 x 1.5 x 40BRIGHT WASHER 13SPRING WASHER B 12HEX. NUT M 12 x 1.5TORQUE 10 Kg-m

VEHIVLE FRONT

MOUNTING PIN FRONT

NYLOC NUT M 16 x 1.5TORQUE - 14-16 Mkg.

MOUNTING PIN REAR(SCRRATED)

-

13

SUSPENSION

4F. REMOVAL/DISMANTLING OF LOWERWISHBONE (Fig. 8)

Unscrew and remove 2 screws holding bracket(torsion bar mounting) to lower wishbone. Takeout the bracket.

● Take out split pin locking castle nut of stub axlebottom ball joint. Properly support stub axle. Pushout the ball joint from stub axle.

● Unscrew and remove two nyloc nuts of pivot pinsholding lower wishbone with mounting bracketson frame, using adaptor (Pt.No. 2699 5890 4101). Push out pivot pins and remove lowerwishbone (Fig.14)

● Unscrew and remove 4 screws holding the balljoint to lower wishbone. Take out ball joint.

● Pry out pivot bushes from lower wishbones, ifnecessary.

● Pry out pivot bushes from lower wishbonemounting bracket, if necessary.

5. INSPECTION OF PARTS

● Check condition of the following for wear, damage.If necessary replace with new ones.

● Antiroll bar for bend, cut, damage etc.

● Rubber links and bushes of antiroll bar.

● Pivot bushes, washer and spindle of upperwishbone assembly.

● Ball joints of upper wishbone and lower wishbone.Check for excessive play in ball joints.

● Rubber boots of top and bottom ball joints. If it isdamaged, check the condition of ball joints. Ifdamaged, replace ball joints. Install new bootswith lithium base grease.

● Shock absorber for leakage etc. Check thecondition of rubber bushes, washer etc.

● Torsion bar spring for sagging, wear cuts etc.

● Bump and rebound stopper for wear and damage.

● Upper wishbone and lower wishbone.

Fig.14 Lower wishbone assembly

6. ASSEMBLY/INSTALLATION PROCEDURE6A. ASSEMBLY / INSTALLATION OF LOWER

WISHBONE

● Assemble lower ball joint on stub axle for 4 x 4version 8 than the lower wishbone.

● If 2 halves of pivot bushes were removed earlierfrom lower wishbone & upper wishbone, fit eachhalf from either sides, using suitable drift.

● Locate lower ball joint on lower wishbone & install2 hex bolt (M12), washer, spring washer, hex. nutand then 2 hex screws (M10), washer, springwasher, hex nut. Tighten M 12 bolts to 10 mkg..torque and M10 screws to 6-7 mkg. torque.

● Fit torsion bar mounting bracket on lowerwishbone with 2 hex screws and washers. Tightenhex screws to 10 mkg. torque.

● Position lower wishbone on chassis frame. Alignpivot bushes and holes on bracket using suitablepunch.

● Insert shims to fill the gap at front pivot. Installpivot pins (serrated pin in the torsion bar mountingbracket) and nyloc nuts. Tighten nyloc nuts to14-16 mkg. torque, using adaptor (Pt. No. 26995890 41 01).

14

SUSPENSION

Fig. 16 - Installation of upper wishbone on vehicle

Fig. 15 - Upper wishbone assembly

TORQUE 8-9 Kg-m

15

SUSPENSION

6B. ASSEMBLY/INSTALLATION OF UPPERWISHBONE (Fig. 16)

● If pivot bushes and spindle were removed earlier,press new pivot bush on upper wishbone usingsuitable drift.

● Insert spindle into upper wishbone and then pressthe other pivot bush.

● Fit washers, spring washers and two M12 screwsconnecting spindle and upper wishbone. Maintainangle 22O & height 30 mm from the flat surfaceof wishbone as shown in Fig.15. Tighten screwsto 8-9 mkg. torque.

● Check the condition of rubber boot of top balljoint. If it is damaged, check the condition of balljoint and replace ball joint if necessary. Install anew boot with lithium base grease.

● Using special tool, mandrel Pt. No. 2654 5890 3203, fit the clip ring of the boot.

● Fit top ball joint on upper wishbone and tighten 4screws with spring washers. Use anaerobiccompound and tighten to specified torque.

● Position upper wishbone assembly on chassisframe. Insert the shims removed earlier. Tighten2 screws connecting the spindle of upperwishbone to the bracket on chassis frame (Fig.16).

● Install stub axle (Refer front axle Group).

6C. INSTALLATION OF FRONT SHOCKABSORBER (Fig.17)

● Install washer, spacer tube and rubber bush onto top mounting bolt of shock absorber.

● Position the shock absorber properly between topmounting bracket on frame and bottom mountingbracket on lower wishbone.

● Install hex bolt in bottom mounting bracket andtighten nyloc nut to 3.5 mkg. torque.

● Install rubber bush, washer and nyloc nut onshock absorber top mounting bolt and tightennyloc nut to 3.5 mkg. torque.

● Take out jack.

Fig. 17 - Installation of shock absorber

16

SUSPENSION

Fig. 19 - Installation of torsion bar

Fig. 18 - Installation of antroll bar

TORSION BAR REAR END

TORSION BAR FRONT END

ANCHOR BOLT

SPHERICAL WASHER

SPACER

WASHER

LOCNUT M12 X 1.5HEX. NUT M12 X 1.5SHOW WASHER TANK

TORSION BAR LEVER

A B

DIMN A DIMN B Remark

6-8 mm 71-74mm For Telcoline Pick-up& crewcab (4x2, 4x4vehicle)

A

71-74 mm

10-12 mm

17

SUSPENSION

6D. INSTALLATION OF FRONT ANTIROLL BAR(Ref. Fig.18)

● Position anti roll bar between the brackets on lowerwishbone.

● Install cup, rubber bush & washer on antiroll barmounting bolt. Insert mounting bolt in mountingbracket on lower wishbone. Install cups, rubberbushes, sleeve, antiroll bar 8 nyloc nut onmounting bolt properly. Tighten nyloc nut suchthat bolt end should project 10 to 12 mm abovenyloc nut.

● Apply silicon grease molykote 33 (medium) onantiroll bar over bearing width of bearing block tobe mounted on chassis frame. Fit bearing blockand mounting clamp with hex. screw, springwasher and bright washer.

● Tighten bearing block clamp mounting screws to4.5 mkg. torque.

● Ensure equal gap between wishbone and antirollbar on both sides.

6E. INSTALLATION OF FRONTWHEELS

● Install wheels on the hub and tighten wheel nutsby hand.

● Remove the supports, supporting chassis longmember.

● Tighten wheel nuts to a torque of 12-15 mkg.

Note

Hold the steering wheel and tighten castle nutsof stub axle top mounting ball joint ancf stub axlebottom mounting ball joint to 13.5 mkg. torque.Lock the castle nuts with split pins.

6F. INSTALLATION OF TORSION BAR (Fig.19)

● Assemble wheels, if removed earlier.

● Jack up chassis from behind front wheels from(RH & LH) side and adjust chassis height to (Topof chassis at the front Location hole)550 ± 3 mm.

(Alternatively adjust the distance between upperwishbone mounting bracket & lower wishbone toappox. 295 mm or angle of lower wishbone toappox. 60 as shown in fig. 20)

● Apply a light coat of ‘Servo Molex grease 3%MoS2' to the splines of torsion bar.

Fig. 20 - Lower wishbone height adjustment

Fig. 21 - Installation of torsion bar

UPPER WISHBONEMOUNTING BRACKET

LOWER WISHBONEMOUNTING BRACKET

295

mm

6O

● ‘R’ and ‘L’ are marked at one end of RH and LHtorsion bars respectively. Install unmarked endof torsion bar RH to the bracket on lowerwishbone of RH side. Similarly install torsion barLH. (Fig. 21)

● Assemble the levers on torsion bar at rear end,such that after putting one nut, 1 to 3 mmprotrusion of the anchoring bolt is maintained.

● Tighten nut up to approx. 68 mm. protrusion ofanchor bolt. Fit lock nut and tighten it.

● Remove jack. Bounce the wheel to settlesuspension.

● Measure front chassis height from the ground. Ifit is not 550 ± 3 mm. adjust it by torsion baranchoring bolt.

18

SUSPENSION

Fig. 23 - Toe -in adjustment

Fig. 22 – Camber angle and castor angle

SHIMS

* IF CASTOR IS NOT WITHIN 3O ± 30'USE ONLY ONE SHIM AT LOCATION ‘A’ OR ‘B’.ADDITION OF SHIM AT ‘A’ WILL REDUCECASTOR ANGLE.ADDITION OF SHIM AT ‘B’ WILLINCREASE CASTOR ANGLE

SECTION - DD

CAMBER SHIMSAS REQUIRED

B**A

VEHICLE FRONT➨

CE

NT

RE

LIN

EO

F V

EH

ICLE

19

SUSPENSION

7. WHEEL ALIGNMENT

Following order is to be maintained while doingwheel alignment

i) Camber angleii) Caster angleiii) Toe-iniv) Wheel lock angle

Caution

Not following the above order will lead to incorrectwheel alignment even though individualadjustments are done correctly.

Note

All adjustments for wheel alignment are to be donein UNLADEN CONDITION ONLY.

Following precautions to be taken beforecommencing wheel alignment.

● Vehicle should be unladen and parked on levelsurface.

● Front tyre should have uniform wear and inflatedto correct pressure.

● Height of front LH & RH Hub cap centre fromground level should be equal (counter check foreven tyre wear and inflation).

● Ensure that hub play is correct.

● Ensure that silent bushes in front suspension arein satisfactory condition.

● Ensure that front suspension fasteners aretightened to specified torque.

● Ensure that there is no play in steering linkagesand suspension ball joints.

NoteIn case wheel alignment is done usingcomputerised wheel aligner, please followinstruction manual of equipment manufacturer.

7A. CAMBER ANGLE ADJUSTMENT (Fig.22)

● While adjusting camber angle nobody should sitinside the vehicle.

● To adjust camber angle, add or remove shimsbetween the chassis frame and the spindle ofupper wishbone mounting.

● Adding shims will reduce the camber angle andremoving shims will increase the camber angle.Adjust camber angle to 0O + 30'.

Note

After addition or removal of shims tighten thebolts to 18 mkg. Recheck camber angle.

7B. CASTOR ANGLE ADJUSTMENT (Fig.22)

● Adding shim at location ‘A’ will reduce the castorand at location ‘B’ will increase the castor. Adjustcaster angle to 3o ± 30' as shown in (Fig. 22)

● Check castor angle. If castor angle is not within3o ± 30' add only one shim of 0.8 mm thick atlocation ‘A’ or ‘B’ as shown in (Fig.22) it willincrease angle by 16'.

Note

Variation in castor between LH/RH sides shouldnot exceed 45'.

After adding shim, tighten the bolts to 18 mkg.torque. Recheck castor angle.

7C. TOE-IN ADJUSTMENT (Fig.23)

● Reading at the front of wheel rim should be lessthan the reading at the rear of wheel rim by 2 to 5mm.

● Toe-in is adjusted by varying the length of tie rodsafter loosening their hex nuts. After adjusting thelength of tie rods recheck toe-in and tighten backthe hex. nuts.

● Increasing length of tie rod will reduce the toe-inand vice-versa. While adjusting toe-in, adjust thelength of both the tie rods by rotating them in thesame direction such that their lengths remainequal at all times.

20

SUSPENSION

Fig. 24 – Wheel lock angle adjustment

26O

Precautions

To maintain steering linkages symmetrical tovehicle centre line, centralise linkages i.e. thedistance between chassis frame long memberoutside face and centre of centre link ball jointshould horizontally equal (55 mm) at both RH &LH sides.

This will ensure that when the wheels are instraight ahead position, steering linkages will alsobe centralised.

7D. WHEEL LOCK ANGLE ADJUSTMENT (Fig.24)

Wheel lock angle is to be set with the help ofstopper bolts fitted in the bracket on chassisframe. Proper adjustment of wheel lock angleensures correct turning circle and also safeguardssteering linkages.

● Place turn tables beneath front wheels, ensurethat wheels are centrally positioned on turn table.

● Make front wheels in straight ahead position andset turn table scale to ZERO.

● Press brake pedal and turn steering to right till areading of 26O to 25O is attained on the left handwheel turn table. In this condition adjust stopperbolt on LH side of chassis bracket to touch the

idler arm and lock adjusting bolt with lock nut.

● Similarly turn steering to left till a reading of 26 to25O is attained on right wheel turn table. In thiscondition adjust stopper bolt on RH side chassisbracket to touch the pitman arm. Lock stopperbolt with lock nut.

21

SUSPENSION

II. REAR SUSPENSION

1. TECHNICAL SPECIFICATIONS

Type : Underslung spring

SPRING

Type : Parabolic leaf spring

2 Stage : Telcoline Pickup/Crewcab

No. of leaves : 3

Thickness : 1-2 leaves 12 mm thick

3rd leaf 15 mm thick

Rate : 5.6 kg/mm first stage10.1 kg/mmsecond stage

REAR SHOCK ABSORBER

Type : Hydraulic, Telescopic,Double acting

Closed length : 366 mm

Open length : 606 mm

Stroke : 240 mm

2. SPECIAL TOOLS

Puller for removal and Pt. No.installation of rubber bush at 2654 5890 32 05spring hanger braket rear andspring eye)

3. TIGHTENING TORQUES

Rear spring ‘U’ bolt : 8 mkg & 4 mkgnut and lock nut respectively

Spring eye bolts, : 16 mkgshackle bolts

Shock absorber eye : 6 - 7 mkgbolts

Antiroll bar mounting : 8 mkgbolts. (to rear axle)

Bolts connecting : 4 mkgantiroll bar toconnecting rod assy.

22

SUSPENSION

4. CONSTRUCTIONAL DETAILS

REAR SPRING

Rear suspension of Telcoline pickup/crewcabvehicle is of 'underslung' type. i.e. Rear spring isconnected to the rear axle at the bottom through‘U’ bolts and guide plate. Fig. 1.

Fig. 1

VEHICLE FRONT

REAR AXLE STOPPER

U BOLT

GUIDE PLATE

REAR SPRINGBRACKET FRONT

RUBBER BUSHING

SPRING PIN REAR SPRING

RUBBERBUSHING

SPRING PIN

SPRING HANGERBRACKET

REAR SPRING

H

H

FITMENT OF REAR SPRING

SECTION - H - HSECTION - G - G

G

SHACKLEPLATE

23

SUSPENSION

Fig. 2

VEHICLE FRONT

FITMENT OF REAR SHOCK ABSORBER

(36.80)

RH

OF

F

RA

ME

LH

OF

RE

AR

AX

LE

REAR SHOCK ABSORBER(Refer fig. 2)

Rear shock absorber is connected inclined to thechassis frame i.e. both side shock absorber areconnected at the top to the rear of rear axle.Shock absorber is eyed at both ends.

5. REMOVAL OF REAR SHOCKABSORBER (Refer fig. 2)

1. Unscrew and remove the nut and boltsconnecting shock absorbers to guide plate.

2. Unscrew and remove the nut holding top endof shock absorber to bracket on chassisframe.

3. Take out shock absorber.

6. INSTALLATION OF REAR SHOCKABSORBER (Refer fig. 2)

1. Connect shock absorber bottom end to guideplate pin. Tighten the nut to 6-7 mkg. torque.

2. Connect shock absorber top end to thebracket on chassis frame and tighten nut to6-7 mkg.

24

SUSPENSION

Fig. 4

2654 5890 3205RUBBER BUSHING REAR SPRING

REMOVAL OF RUBBER BUSH FROM SPRING EYE

Fig. 5

REMOVAL OF RUBBER BUSHFROM SPRING HANGER BRACKET

SPRING HANGERBRACKET (REAR)

RUBBER BUSHING2654 5890 3205

Fig. 3

7. REMOVAL OFREAR SPRING ASSEMBLY

1. Place suitable wheel chocks on front wheels.

2. Unscrew and remove locknuts of U boltsconnecting rear spring and rear axle. Alsoloosen the nuts slightly, but do not take themout.

3. Jackup the vehicle (Fig. 3) until wheels areoff the ground. Support chassis frame longmember with suitable supports, in front of rearspring front bracket.

4. Unscrew and remove nuts of U bolts. Takeout U bolts, guide plate and rear axle stopper.Fig. 1.

5. Remove nyloc nuts of spring eye pins at frontand rear eyes of the spring. Unscrew andremove nyloc nuts. Take out spring pins.

6. Remove rear spring assembly out.

7. Remove spring eye bushes from spring if theyare damaged.

8. INSPECTION

Inspect following parts for wear/damages. Replacewith new ones, if necessary.

1. Shock absorber

2. Rear spring, spring eye bush, shackle plates,pins and U bolts.

Note

i. In case rubber bushing on spring eye andspring hanger bracket (rear) is defective,remove defective rubber bush using specialtool Pt. No. 2654 5890 32 05. Fig. 4 & 5.

ii. Check the condition of friction pads betweenspring leaves. If found damaged or dislodged,install new friction pads in position.

iii. Check the condition of spring leaves. If founddamaged / broken, dismantle rear springassembly and replace the defective leaf alongwith friction pads with new ones.

25

SUSPENSION

Fig. 6

INSTALLATION OF RUBBER BUSH IN SPRING EYE

2654 5890 3205 RUBBER BUSHINGREAR SPRING

9. INSTALLATION OF REARSPRING ASSEMBLY

1. Fit new spring eye bushes on spring front eyeif removed earlier, using drift Pt. No. 26545890 32 05. Fig. 6.

2. Fit new spring eye bush in spring bracket(rear) using drift Pt. No. 2654 5890 32 05.Fig. 7.

3. Connect shackle plates to the spring bracket(rear) with pin and nyloc nuts. Tighten thenyloc nuts to 14 mkg. torque. Lock nyloc nuts.

4. Place the spring assembly under rear axle.Assemble front end of spring assembly tospring bracket (front). Align holes on springeye bush and spring bracket. Install pin,tighten castle nut to 14 mkg. torque. Locknyloc nuts.

5. Jack up rear axle, lift rear spring, align holeof spring eye bush at rear with hole onshackle plates. Insert pin, tighten nyloc nutto 14 mkg. torque. Lock nyloc nuts.

6. Remove the support below chassis frame longmember, remove the jack below rear axle, liftthe wheel, align the centre bolt of rear springwith hole on spring seat of rear axle.

7. Install U clamps, with rear axle stopper onthe rear axle in position; keep the guide platein position, tighten nuts of U clamps to 8mkg. torque and locknuts to 4 mkg. torque.

Fig. 7

INSTALLATION OF RUBBER BUSHIN SPRING HANGER BRACKET

SPRINGHANGERBRACKET(REAR)

2654 5890 3205 RUBBER BUSHING

11

FRONT AXLE - 4X2

FRONT AXLE - 4X2

1

FRONT AXLE - 4X2

INTRODUCTION :

The hub which is mounted on taper roller bearings on

the stub axle is independently suspended with the

chassis frame. The stub axle is pivoted on two ball

joints, upper and lower.

This manual provides information on removal/

installation of front hub and adjustment of wheel

bearings.

It also provides information on removal / installation

of stub axle assembly.

3

FRONT AXLE - 4X2

CONTENTS :


1. A. Technical specifications 4

B. Adjustment data 4

C. Lubricants 4

D. Tightening torques 4

2. Special tools 5

3. A. Dismantling of front axle 6

B. Removal / dismantling of front hub assembly 6

C. Removal of stub axle assembly 7

D. Dismantling of stub axle assembly 7

4. Inspection of parts 7

5. Assembly installation of parts

A. Assembly of stub axle 8

B. Installation of stub axle 8

C. Assembly / installation of front hub 9

D. Installation of hub on stub axle 10

4

FRONT AXLE - 4X2

A. TECHNICAL SPECIFICATIONS

FRONT AXLE

Type Independently suspendedstub axle and hub

B. REPAIR/ADJUSTMENT DATA

Axial play of hub bearing 0.03 to 0.06 mm

C. LUBRICANTS

Front hub to be packed with Lithium base 80 gm per hubgrease LIT MP. 301.

D. TIGHTENING TORQUES (mkg)

Top ball joint (at stub axle) 13.5

castle nut

Bottom ball joint (at stub axle) 13.5castle nut

Bolts connecting tie rod arm to 10 to 12stub axle M 12

Bolts connecting disc assy. and front hub 5.5 - 6.5

Bolts connecting caliper assy. to 6.8 to 8.3stub axle

Bolts connecting top ball joint to top wish bone 3

Bolts connecting bottom ball joint to lower wish bone 6.5 for M10, 9.7 for M12

Wheel nuts 12 to 15

Castle nuts of tie rod ball joints 7 to 9

5

FRONT AXLE - 4X2

SPECIAL TOOLS FOR INDEPENDENT FRONT AXLE (Applicable for Tata Motors Hubs).

Sr. No. Description Part No.

1. Puller for front hub. 2654 5890 33 01

2. Rocker for removal of front 2654 5890 33 02hub inner bearing with oilseal.

3. Rocker for removal of front 2654 5890 33 03hub outer bearing outer race.

4. Puller for tie rod ball joints 2654 5890 33 04

5. Puller for removal of upper 2654 5890 32 01and lower ball joints

6. Mandrel for installation of 2654 5890 32 03clip ring on ball joint bellows

7. Drift for installation of oil 2654 5890 35 04seal in front hub (to be usedwith handle 2640 5890 3511).

8. Drift for installation of 2654 5890 35 07

i) Front hub outer bearingouter race

ii) Front hub inner bearingouter race. (to be used withhandle 2640 5890 3511).

9. Handle for drift (to be used 2640 5890 35 11with 2654 5890 35 03. 26545890 35 04, 2654 5890 35 07)

10. Drift for installation of 2654 5890 35 11

i) Seal race on stub axle

11. Drift for installation of front 2651 5890 33 08hub outer bearing inner racewith cage on stub axle

6

FRONT AXLE - 4X2

3. DISMANTLING OF FRONT AXLE

A. REMOVAL OF FRONT WHEELS :

a. Place wheel chokes on both sides of rearwheels.

b. Loosen front wheel nuts.

c. Keep the jack below long member behind frontwheel and jack up (Fig. 1 & 2). Support framelong member behind front wheels with suitablesupport.

d. Similarly jack up the other side and supportlong member.

e. Unscrew and remove wheel nuts.

f. Remove front wheels.

B. REMOVAL / DISMANTLING OF FRONT HUBASSEMBLY

a. Disconnect front brake hose from brake bundypipes on the bracket on chassis frame. Closebundy pipes with plugs to avoid brake fluid loss.

b. Disconnect brake hose from caliper by takingout banjo bolt.

c. Unscrew and remove two screws connectingcaliper assy to stub axle and remove caliperassy from stub axle.

d. Unscrew and remove cap screws connectinghub cover and hub, and remove hub cover withgasket.

e. Unscrew cap screw on split nut.

f. Unscrew and remove split nut from stub axle.

g. Remove thrust washer from stub axle.

h. Using puller part no. 2654 5890 33 01, removefront hub assy. with disc from stub axle.

i. Remove puller from hub.

C. DISMANTLING OF FRONT HUB ASSY.

a. Take out the inner race with cage of outer bearingfrom hub assy.

b. Using special tool, Rocker, Pt. No. 2654 589033 03 and a suitable handle remove outer raceof outer bearing.

c. Using special tool, Rocker, Pt. No. 2654 589033 02 and a suitable handle remove innerbearing with oil seal.

d. Clean all parts thoroughly.

Fig. 1 Pickup

Fig. 2 Crew cab

7

FRONT AXLE - 4X2

D. REMOVAL / DISMANTLING OF STUB AXLEASSEMBLY

Removal -

a. Release load on torsion bar fully. (Fig.3)

b. Take out split pins locking castle nuts of balljoints at tie rod end on stub axle.

c. Using Puller Pt. No. 2654 5890 33 04 push outball joints of tie rods from tie rod arms.

d. Take out split pins locking castle nuts of topand loosen the castle nuts ball joint of stubaxle.

e. Unscrew and remove 4 screws holding ball jointassy. to the top wishbone. Take out ball jointassy.

f. Push out top ball joint from stub axle usingspecial tool Pt. No. 2654 5890 32 01. Properlysupport stub axle.

g. Unscrew 4 screws of lower ball joint on lowerwishbone. Take out stub axle along with balljoint.

h. Remove ball joint from stub axle with a mallet.

E. DISMANTLING OF STUB AXLE ASSEMBLY

a. Unlock tab of 2 bolts connecting tie rod arm tothe stub axle. Unscrew and remove bolts.Remove tie rod arm from stub axle.

b. Unscrew and remove 3 screws connecting dustshield to stub axle. Remove dust shield.

c. In case oil seal race on stub axle is worn out/damaged, take out seal race by hammering.

4. INSPECTION OF PARTS

1. Check condition of bearing seats and oil sealseat on hub for wear/scoring marks. Ifnecessary replace with new hub.

2. Check condition of wheel bolts for worn out /stripped threads. Replace bolts if necessary.Bolts are press fitted into hub.

3. Check condition of bearings for wear/pittingmarks. If necessary replace with new ones.

4. Check condition of bearing seats on stub axlefor wear/scoring marks, condition of threads ofstub axle for worn out/stripped threads, conditionof seal race for wear/scoring marks etc.If necessary, replace with new stub axle.

5. Check condition of split nut for stripped or wornout threads, ease threads, if necessary. Changesplit nut if necessary.

6. Check condition of ball joints. Check forexcessive play in ball joints. If necessaryreplace with new ones.

While replacing ball joints check condition oftaper bore in stub axle.

7. Check condition of rubber boots of top andbottom ball joints. If it is damaged, dismantlethe boot and install a new boot after ensuringthat enough grease is available inside ball joint.

Fig. 3

8

FRONT AXLE - 4X2

5. ASSEMBLY / INSTALLATION OF PARTS

A. ASSY. OF STUB AXLE

a. Assemble tie rod arm to stub axle (if removedearlier) and tighten bolts to specified torque.Lock bolts with tab washers.

b. Fit back dust shield on stub axle (if removedearlier) and tighten the screws.

c. In case seal race is removed earlier, assemblea new seal race on stub axle using driftPt.No. 2654 5890 3511 Fig. 4.

d. Inspect condition of rubber boots of ball joints.If damaged, remove boot, and install a newboot after ensuring that enough grease isavailable inside. Using mandrel Part No. 26545890 3203, fit circlip of boot in position.

If there is excessive play in ball joint, replaceball joint assy. with a new one.

B. INSTALLATION OF STUB AXLE

a. Install lower ball joint in to stub axle & tightenfour screws on lower wishbone. Tighten castlenut.

Fit stub axle assembly between upper and lowerwishbone. Tighten 4 screws of lower ball jointon lower wishbone.

b. Install upper ball joint in to stub axle and tightenfour screws in upper wishbone. Tighten castlenut.

c. Connect tie rod ball joints. Tighten castle nutsto specified torques and fit split pins.

Note : Tightening of castle nuts of upper and lowerball joints to specified torque can be done afterconnecting steering linkages, if it is notpossible at this stage.

Fig. 4

2654 5890 35 11

SEAL RACE

STUB AXLE

INSTALLATION OF SEAL RACE ON STUB AXLE

9

FRONT AXLE - 4X2

C. ASSY / INSTALLATION OF FRONT HUB :

I. ASSEMBLYa. Before proceeding to assembly of hub, ensure that

all parts are cleaned properly; especially thebearings.

Smear little grease on the OD of inner bearing outerrace. Press outer race in hub using

1) Drift 2654 5890 35 07

2) Handle 2640 5890 35 11. Fig. 5

b. Pack roller cage of inner bearing with grease andlocate it in hub.

c. Smear little grease on the OD of the oil seal(always fit a new oil seal) and press seal in hubusing

1) drift 2654 5890 35 04

2) Handle 2640 5890 35 11. Fig. 6

d. Smear little grease on OD of outer bearing outerrace and press outer race in hub using

1) Drift 2654 5890 35 07

2) Handle 2640 5890 35 11. Fig.7

e. Pack space between hub bearings with wheelbearing grease.

Fig. 5

Fig. 6

INSTALLATION OF FRONT HUB INNERBEARING OUTER RACE

2640 5890 35 11

2654 5890 35 07

2640 5890 35 11

2654 5890 35 04

INSTALLATION OF OIL SEAL IN FRONT HUB

Fig. 7

2640 5890 35 11

2654 5890 35 07

INSTALLATION OF FRONT HUBOUTER BEARING OUTER RACE

10

FRONT AXLE - 4X2

II) INSTALLATION OF HUB ON STUB AXLE (Fig. 8).

a. Slide assembled hub on stub axle.b. Insert inner race with roller cage of outer bearing

into stub axle after packing rollers with grease, usingdrift 2651 5890 33 08. Insert thrust washer andscrew on the split nut.

c. Wheel Bearing Adjustment:- Fit dial gauge on a magnetic stand. Fit magnetic

stand on hub and adjust spindle of dial gauge in sucha way that it rests against the face of stub axle. Dialgauge should have a pre-load of approx. 2 mm.

- Tighten split nut with suitable spanner fully. Loosennut slightly, gently tap hub all around with a mallet.

- Check axial play of hub on the dial gauge bypulling and pushing hub by hand and go ontightening split nut until play is within0.03 - 0.06 mm.

- Tighten cap screw on split nut.- Check and ensure again axial play of hub, that it is

within limit of 0.03 - 0.06 mm.- Fit hub cover with gasket and tighten cap screws.

Fill approx. 30 gms grease in cover before fitting.d. Install caliper assy on disc and tighten screws

connecting the caliper assy to stub axle to 6.8 -8.3 mkg torque.

e. Connect one end of brake hose to caliper assy bybanjo bolt.

f. Connect other end of brake hose to bundy pipe onbracket on chassis frame. Install the clip.

g. Fill brake fluid in brake fluid container and bleedthe system.

D. INSTALLATION OF THE FRONT WHEELSa. Install front wheels on hub assy and tighten

wheel nuts by hand.b. Remove supports, supporting chassis long member.c . Tighten wheel nuts to a torque of 12-15 mkg.

NOTE :Front hubs manufactured by Tata Motors & Dana Spicerare used in selection in 4x2 version.Procedure given in this section is applicable only forTata Motors front hubs.Repair procedure for Dana Spicer front hub & DanaSpicer rear hub are same. Please refer relevant portionof Spicer rear axle for repair of Spicer front hubs.Spicer hubs only are used for front wheels in 4x4version. Dismantling, inspection, repairs & assemblyprocedure for spicer front hubs used in 4x4 version &special tools required are same as that of spicer rearhubs.

ASSY. FRONT AXLE (TELCO)

Fig. 8

ASSY. FRONT AXLE (DANA SPICER)

Fig. 9

51

FRONT AXLE - 4 X 4

FRONT AXLE - 4X4

1

FRONT AXLE - 4 X 4

INTRODUCTION :

Live Front Axle (Dana Spicer) has following unique

features.

Centre section of Front Axle Assembly is an integrated

type axle housing. Axle bearings are lubricated with

hypoid lubricant. Thus it does not require grease.

Automatic hub lock at the wheel end is very convenient

for user with its characteristic of automatic locking by

engaging transfer case & of free wheeling possibility

by reversing the vehicle. The response is very sharp

with angle of wheel rotation needed for locking &

unlocking being mere ninty degrees.

The constant velocity (CV) shafts are connected

between side gear in differential case and spindle

assembly. These shafts provide power transfer

maintaining a constant shaft speed regardless of

operating angles, while allowing for steering and

suspension movement.

3

FRONT AXLE - 4 X 4

CONTENTS :


FRONT LIVE AXLE ASSEMBLY (DANA SPICER) :

1. Construction 4

2. Specification & service data 5

3. Special tools list 6

4. Removal of wheel end with CV shaft from vehicle 7

Disassembly & Assembly :

(i) Wheel end assembly 7

(ii) Carrier Centre section 13

(iii) C. V. joint shafts 27

5. Trouble shooting - axle assembly 33

AUTOMATIC LOCK HUB (DIVGI WARNER) MODEL 1704 - 000 - 002

6. Introduction 34

7. Specifications 36

8. Diagnosis 37

9. Dis-assembly inspection & lubrication 38

10. Lubrication & Assembly 40

11. List of Serviceable Parts & Tools 43

2 - WAY LOCK FREE RUNNING HUB

12. Construction 44

12. Removal and Installation of free running hub on vehicle 45

13. Solution to Noise Problem 47

14. Procedure for replacing TF hub lock with Divgi Warner hub lock 48

4

FR

ON

T A

XL

E - 4 X

4

Fig. 1

CO

NS

TR

UC

TIO

N O

F F

RO

NT

LIV

E A

XL

E

No

te : Dust shield has been

deleted in recent version.

5

FRONT AXLE - 4 X 4

SPECIFICATION AND SERVICE DATA

Type : Single reduction, with hypoid gears

Independently suspended, with automatic hub locks.

Axle ratio : 4.875 (39 / 8) Facelift version

4.1 (41/10) OR 4.56 (41/9) Non-Facelift version

Weight of axle including brake disc : 105 Kg ± 2.5 %

Amount of grease required at each wheel end : 92 gms

Hub bearing play : 0.00 to 0.10 mm

Maximum torque to rotate Hub, : 2.30 Nmwhen end play is 0.00 mm

To adjust bearing (spindle assembly)

(i) Torque inner locknut and lock : 68 Nm

(ii) Install outer locknut : 203 to 305 Nm

Oil Capacity : 1.2 Lit. ± 3%

Lubricant change Interval : At every 40,000 km (24,000 miles) of operation

Tightening Torque

Cover Screws : 38-45 Nm

Fill Plug : 20-34 Nm

Differential Bearing Cap screws : 47-68 Nm

Ring Gear Screws : 95-122 Nm

Drive Pinion Nut : 217 Nm Min.

Drain Plug : 27-34 Nm

Spindle to Knuckle Nuts : 34-47 Nm

Brake Disc to Hub Flange : 58-70 Nm

Hub Lock Screws to Hub : 54-63 Nm

Breather : 20-34 Nm

Mounting Brackets to Carrier : 54-75 Nm

Pinion Bearing Preload

Torque to rotate drive pinion only : 1.7-3.9 Nm

Backlash Specification

Ring gear to pinion gear : 0.13 mm to 0.23 mm(to be checked at 3 different locations)

Maximum permissible variation : 0.08 mmbetween checked points.

6

FRONT AXLE - 4 X 4

SPECIAL TOOLS FOR INDEPENDENT FRONT LIVE AXLE (DANA SPICER).


1. Dolley to press oil seal in hub 2704 5890 33 012. Dolley for pressing oil seal in tube 2704 5890 33 023. Dolley to press cup in hub (outer) 2704 5890 33 034. Dolley to press cup in hub (inner) 2704 5890 33 045. Dolley for pressing Needle Roller Bearing in the tube 2704 5890 33 056. Dolley for pressing Cylindrical Roller Bearing in housing 2704 5890 33 067. Adaptor to remove cup from hub (inner) 2704 5890 33 078. Adaptor to remove cup from hub (outer) 2704 5890 33 089. Dummy Bearing 2704 5890 33 0910. Adaptor to remove pinion inner cup 2704 5890 33 1011. Handle for dollies 2704 5890 33 1112. Expander from M 30 carrier 2704 5890 33 1213. Pinion height setting gauge 2704 5890 33 1314. Dolley for pressing outer pinion bearing cup in housing 2704 5890 33 1415. Adaptor to remove pinion outer cup 2704 5890 33 1516. Dolley for pressing inner bearing cone on pinion 2704 5890 33 1617. Height setting gauge master block 2704 5890 33 1718. Check nut spanner 2704 5890 33 1819. Dolley to press oil seal in spindle 2704 5890 33 1920. Dolley to press bearing cone in spindle 2704 5890 33 2021. Dolley for pressing inner pinion bearing cup in housing 2704 5890 33 2122. Adaptor to remove differential bearing 2704 5890 33 2223. Adaptor to remove pinion inner bearing 2704 5890 33 2324. Puller to remove right side bearing from flange carrier 2704 5890 33 2425. Dolley for pressing differential case bearing 2704 5890 33 2526. Adaptor to remove bearing cone on spindle 2704 5890 33 2627. Dolley to press needle roller bearing in spindle 2704 5890 33 2728. Bearing puller 2704 5890 33 2829. Adaptor plug spindle 2704 5890 33 2930. Plain pliers, snap ring 2704 5890 33 3031. Tank pliers - snap ring 2704 5890 33 3132. Clamp crimper 2704 5890 33 3233. Ball assembly tool 2704 5890 33 3334. Puller 2654 5890 33 04

Following tools are common with Rear Axle (Spicer)35. Holder yoke 2698 5890 35 0536. Press 2698 5890 35 1537. Adaptor ring 2698 5890 35 1638. Slide hammer puller 2698 5890 35 0739. Installer pinion oil seal 2698 5890 35 1340. Handle universal 2698 5890 35 0641. Drive square for drain plug 2698 5890 35 24

7

FRONT AXLE - 4 X 4

REMOVAL OF WHEEL END WITH CV SHAFTFROM VEHICLE

Place wheel chocks on both sides of rear wheels.

Disengage the hub locks if need be, by shifting thevehicle to 2H mode.

Loosen front wheel nuts.

Jack up front wheels and support them suitably.

Unscrew and remove wheel nuts. Remove frontwheels.

Disconnect front brake hoses and plug them to avoidbrake fluid loss. Unscrew and remove caliperassemblies from stub axles.

Release torsion bar load fully. Loosen steering knuckleball joint nuts top and bottom, but do not remove.

Remove tie rod assembly nut.

Disconnect tie rod from knuckle by pushing out balljoint of tie rods, using puller pt. no. 2654 5890 33 04.

Caution : Do not allow CV shaft to hangunsupported. Damage to out board and inboard CV joint may result.

Wrap axle shaft with layers of tape. Fig. 2

Tie axle shaft to chassis frame with a rope, in order tohold the shaft level while knuckles are being removed.

Remove nuts from the ball joint and remove knuckle.Tap with mallet, if required. Hold axle shaft with onehand next to the axle housing, gently pry the shaftassembly loose from the side gear with a large screwdriver.

Hold axle shaft at out board CV joint and removesupporting wire.

Carefully remove shaft from axle housing.

Wheel End Assembly

(Disassembly is done on a work table.)

Install wheel end assembly on a soft jaw vice.

Remove six allen screws which secure hub - lockassembly. Fig. 3

Fig. 2

Fig. 3

LOCK

AU

TO

AU

TO

LOCK

Tape

8

FRONT AXLE - 4 X 4

Remove hub - lock assembly.

Note : 1. The knob should be at lock position. Fig. 4(only for TF hub lock)

Note : 2. Hub - lock assembly is a non - serviceablecomponent. If it is established that problem isin hub - lock, it is to be replaced with a newone. (only for TF hub lock)

Remove snap ring from axle shaft. Fig. 5

Remove washer.

Remove outer & inner brake assembly (only for TFhub lock)

Remove axle shaft.

Using a socket, spanner pt. no. 2704 5890 3318remove spindle lock nut, lock washer and inner wheelbearing adjusting nut. Fig. 6

Note : Pin on wheel bearing adjusting nut engagesto a hole in lock washer. During removal, takecare not to damage pin. Replace wheel bearingadjusting nut, if pin is found bent or damaged.

Remove spindle assembly by pulling steering knucklefrom hub.

Fig. 4

Fig. 5

Fig. 6

AU

TO

LOCK

AU

TO

LOCK

9

FRONT AXLE - 4 X 4

Remove outer bearing cone and roller assembly.

Remove outer bearing cup from hub, using adaptorPt. no. 2704 5890 3308.

Turn hub upside down.

Remove inner bearing cup from hub using AdaptorPt. no. 2704 5890 3307.

If necessary, remove five bolts and lock washers whichsecure hub and brake disc. Fig. 7

Separate hub and brake disc.

Fig. 7

Fig. 8

Spindle Assembly :

Place spindle assembly on work table.

Remove inner bearing from spindle as shown on Fig.8 using.

1. Adaptor ring Pt. no. 2698 5890 3516

2. Press Pt. no. 2698 5890 3515

3. Adaptor, plug spindle Pt. no. 2704 5890 3329

4. Adaptor to remove bearing cone on spindle.Pt. no. 2704 5890 3326.

UNSCREW

1

23

4

10

FRONT AXLE - 4 X 4

Remove hub seal.

Remove six nuts which hold spindle on knuckle.

Fig. 9

Fig. 9

Fig. 10

Fig. 11

Remove spindle from steering knuckle by tapping withsoft hammer. Fig. 10

Note : Striking the threaded portion will damagespindle.

Place spindle in a soft - jaw vise.

Remove spindle needle bearing and seal using Bearingpuller Pt. no. 2704 5890 3328. Fig. 11

Cleaning and Inspection

Clean hub and brake disc with a metal part cleaner.

Inspect parts for wear and damage. If brake disc isheavily worn or damaged, replace it.

Inspect bearings and cones for scoring and wearmarks. Replace if required.

Inspect pin on wheel bearing adjusting nut. If pin isfound bent or dislodged, replace adjusting nut.

Clean spindle with metal cleaning solvent and dry it.

Inspect inner and outer bearing seating area in spindle.If scored/damaged, replace spindle.

11

FRONT AXLE - 4 X 4

ASSEMBLY

Install brake disc on a soft - jaw vise.

Assemble hub on brake disc with five bolts and lockwashers.

Torque bolts to specified value.

Assemble outer bearing cup using. Dolley Pt. no. 27045890 3303. Fig. 12

Assemble inner bearing cup using. Dolley Pt. no. 27045890 3304 Fig. 13

Pack spindle, inner and outer bearings with specifiedgrease.

Mount the spindle suitably.

Assemble spindle needle bearing using Dolley Pt. no.2704 5890 3327. Drive the bearing until tool bottomsout against spindle.

Note : Make sure that the bearing number on the raceis placed against the tool.

Assemble spindle to steering knuckle. Tighten sin nutsto specified torque. Fig. 14

Assemble new hub seal.

Assemble inner bearing to spindle using. Dolley Pt.no. 2704 5890 3320.

Apply grease to assemble bearing on spindle, ifrequired.

Mount hub and brake disc assembly suitably.

Assemble spindle onto hub and brake disc assembly.

Note : Small amount of rocking motion of steeringknuckle may be required.

Assemble outer bearing cone onto spindle.

Assemble inner wheel bearing adjusting nut.

Note : Ensure that lock pin is towards outside (toolside).

Fig. 12

Fig. 13

Fig.14

12

FRONT AXLE - 4 X 4

Torque inner adjusting nut to 68 Nm. using spannerPt. no. 2704 5890 3318 Fig. 15

Rotate hub, loosen inner adjusting nut 90 degreesmaximum and assemble lock washer by turning inneradjusting nut so that pin on adjusting nut aligns with ahole in lock washer.

Install lock nut and torque 203-305 Nm.

Final bearing adjustment to have 0.00 to 0.10 mmtotal end play.

Maximum torque to rotate the hub is 2.3 Nm (Whenend play is 0.00)

Install axle shaft in spindle.

Reassemble assembly outer brake.

Install washer and reassemble the snap ring to axleshaft.

Reassemble hub - lock assembly

Note : Refer hub lock installation and removalprocedure.

Screw in allen screws and tighten to specified torque.

Fig. 15

Fig. 16

Wheel End Components :

13

FRONT AXLE - 4 X 4

CARRIER CENTRE SECTION

DISASSEMBLY

Remove wheel ends, steering knuckles and both outboard shaft assemblies.

Mount axle on a suitable stand.

Drain oil by unscrewing drain plug.

Remove cover plate screws, and cover plate.

Clean the liquid gasket on housing & cover matingsurfaces.

Remove axle shaft snap ring. Fig. 17

Inspect snap ring, discard if damaged.

Remove axle shaft. Fig. 18

Remove mounting bracket. Fig. 19

Remove the mounting bracket from centre section.

Remove RH carrier trunnion seal and LH tube sealusing puller Pt. no. 2698 5890 3507.

Note : Discard seals and replace with new onesduring assembly. Both seals areinterchangeable.

Remove LH side needle roller bearing from tube usingbearing puller Pt. no. 2704 5890 3328.

Fig. 17

Fig. 18

Fig. 19

14

FRONT AXLE - 4 X 4

Carrier Section

Remove bearing caps. Fig. 20

Note mating letters stamped on caps and carrier.

Mount Expander Pt. no. 2704 5890 3312 to housing &expand housing. Do not spread carrier over 0.50 mm.Use dial indicator. Fig. 21

Remove dial indicator.

Pry differential case from carrier with two pry bars.Fig. 22

Remove Expander.

Remove RH side bearing from flange carrier usingpuller Pt. no. 2704 5890 3324.

Remove differential side bearings using :

Press Pt. no. 2698 5890 3515

Adaptor ring Pt. no. 2698 5890 3516

Adaptor to remove differential bearing Pt. no. 27045890 33 22. Fig. 23.

Identify shims, bearing cups and bearing cones as tofrom which side they were removed.

Caution : When pulling bearing, differential assemblymay fall and get damaged.

Fig. 21

Fig. 22

Fig. 23Fig. 20

DIAL INDICATOR/MAGNETIC BASE

DIFFERENTIALHOUSING

SPREADER

SPREADER HOLE TO SPREADERHOLE

BEARING CAPS

M A T I N GLETTERS

15

FRONT AXLE - 4 X 4

Remove ring gear screws and ring gear. Fig. 24

Note : Protect gear teeth from getting damaged.Discard the ring gear screws.

Case Disassembly

Drive out roll pin securing pinion mate shaft. Fig. 25

Remove pinion mate shaft. Fig. 26

Remove pinion mate gears by rotating side gears.

Remove side gears. Fig. 27

Fig. 25

Fig. 26

Fig. 27Fig. 24

DIFFERENTIALSIDE GEAR

DIFFERENTIALPINIONSHAFT

DIFFERENTIALPINION GEAR

DIFFERENTIALPINION GEAR

16

FRONT AXLE - 4 X 4

Drive Pinion Removal

Turn nose of carrier to vertical position and removepinion nut and end yoke. Fig. 28

Note : Discard pinion nut.

Remove pinion by tapping. Fig. 29

Note : Do not allow to pinion to fal. It can getdamaged or strike foot. Discard collapsiblespacer.

Pull out pinion seal using puller slide hammer Pt. no.2698 5890 3507 Fig. 30

Note : Discard seal.

Remove pinion outer bearing cone and outer slinger.

Remove pinion inner bearing cup using Adaptor Pt.no. 2704 5890 3310. Fig. 31

Fig. 29

Fig. 30

Fig. 31Fig. 28

17

FRONT AXLE - 4 X 4

Remove pinion outer bearing cup using Adaptor Pt.no. 2704 5890 3315 Fig. 32

Caution : Do not nick carrier bore.

Note : Pinion inner slinger is located between pinioninner bearing cone and pinion gear.

Remove pinion inner bearing. using :

1] Press Pt. no. 2698 5890 3515.

2] Adaptor ring Pt. no. 2698 5890 3516.

3] Adaptor to remove pinion inner bearing Pt. no. 27045890 3323.

Remove pinion inner slinger.

ASSEMBLY

Shaft Bearing & Seals.

Install RH roller bearing assembly into the carriertrunnion with Dolley Pt. no. 2704 5890 3306 until thetool bottoms out against carrier.

Note : Make sure that the bearing number on race isplaced against tool.

Install LH needle bearing assembly into axle tube withDolley Pt. no. 2704 5890 3305.

Note : Make sure that bearing numbers on race isplaced against tool.

Assemble oil seal in tube with Dolley Pt. no. 27045890 3302.

Carrier Section

Inspect side gears & pinion mate for wear & damage.Replace gears as a complete set. Do not mix newgears with old gears.

Discard old side gear thrust washers and pinion matespherical washers. New washers have to be usedduring assembly.

Apply grease to side gear thrust washers and hubs ofside gears.

Assemble both side gears.

Apply grease to pinion mate spherical washers andpinion mate gears.

Assemble pinion mate gears. Fig. 33

Fig. 32

Fig. 33

18

FRONT AXLE - 4 X 4

Align holes of the gears with case and assemble shaft.Fig. 34

DRIFTDIFFERENTIALPINIONSHAFT

PEEN METALOF CASE

Fig. 34

Fig. 35

Fig. 36

Ensure that vertical lock pin hole is lined up with thatof the case, and that pinion mate washers are in placeand lined up with gear and case.

Assemble roll pin. Fig. 35

Stake (peen) metal of case over roll pin at two places1800 apart to lock differential pinion shaft on case.Fig. 36

19

FRONT AXLE - 4 X 4

Fig. 38

Fig. 37

RING AND PINION GEAR ASSEMBLYRing gear and pinion is supplied as a sets only.They are matched with each other duringmanufacture. Matching numbers on both pinion andring gear are etched for verification. Fig. 37 or 38.

If a new gear set is used, verify numbers on pinionand ring for matching before proceeding withassembly.

Standard mounting distance from center line of ringgear to back face of pinion is 92.08 mm. Thisdimension is controlled by selecting shims, whichare positioned between the inner pinion bearingcone and pinion gear. Best running position of gearset is achieved by proper shim selection.

This dimension for rear axle will be different.

On the bottom face of pinion a numbered isetched. It can be a plus (+) number, a minus (-)number or Zero (0). Required pinion shim selectionis achieved with help of this number.

If alphabet "m" appears on pinion face shimselection has to be done in mm (Metric).

If alphabet "m" does not appear on pinion faceshim selection has to be done in inches (English).

m

Shims with different thicknesses are available forselection.

Use tables on next page as a guide for selectingcorrect thickness of shims either for addition or forsubtraction from old shim pack.

Fig. 37 shows ring and pinion etched with inchidentification. Refer Table A.

Fig. 38 shows ring and pinion etched with metricindentification. Refer Table B.

Please refer tables given below for calculations :Example 1

In metric In inches

No punched on removed + 8m + 3pinion

No punch on new pinion - 5m - 2

Value derived from table + 0.13 + 0.005

Thickness of shims in x yOE assembly

Thickness of shims to be x + 0.13 y + 0.005selected for new ring/pinion

Example 2

In metric In inches

No punched on removed - 5m - 3pinion

No punch on new pinion + 5m + 4

Value derived from table - 0.1 - 0.007


Thickness of shims to be x - 0.1 y - 0.007selected for new ring/pinion

20

FRONT AXLE - 4 X 4

TABLE A

Old Pinion New Pinion Marking (English) (Value in Inches)

Marking (English) -4 -3 -2 -1 0 +1 +2 +3 +4

+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0

+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003

0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004

-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005

-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006

-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007

-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

TABLE B

Old Pinion New Pinion Marking (Metric) (Value in mm)

Marking

(Metric) -10 -8 -5 -3 0 +3 +5 +8 +10

+10 +.20 +.18 +.15 +.13 +.10 +.07 +.05 +.02 0

+8 +.18 +.16 +.13 +.11 +.08 +.05 +.03 0 -.02

+5 +.15 +.13 +.10 +.08 +.05 +.02 0 -.03 -.05

+3 +.13 +.11 +.08 +.06 +.03 0 –.02 -.05 -.07

0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10

-3 +.07 +.05 +.02 0 -.03 –.06 -.08 -.11 -.13

-5 +.05 +.03 0 –.02 -.05 –.08 –.10 -.13 -.15

-8 +.02 0 -.03 -.05 -.08 -.11 -.13 –.16 –.18

-10 0 -.02 –.05 -.07 –.10 -.13 -.15 –.18 –.20

Note: Please observe the marking on pinion. If ‘m’ is found etched on the face, refer table B. If not refer tableA.

21

FRONT AXLE - 4 X 4

PINION POSITION SHIM SELECTION

Install height setting gauge master block Pt. no. 27045890 3317 over inner bearing cup seat.

Install dial gauge on Pinion height setting gauge Pt.no. 2704 5890 3313.

Set dial gauge to 0 (zero), on a surface plate.

Install special tool depth gauge on differential sidebearing housing.

Install dial gauge, such that the plunger is in contactwith pinion master.

Rock the depth gauge.

Record the reading when indicator is at the highestpoint. Let it be 'x' Fig. 39

To calculate the shim thickness proceed as follows.

Shim thickness required = x - etched value onpinion (when etched+ve)

= x + etched value onpinion (when etched-ve)

Assembly pinion bearing cup

Drive pinion inner bearing cup into carrier using dolleyPt. no. 2704 5890 33 21. Fig. 40

Assemble pinion outer bearing cup into carrier usingdolley Pt. no. 2704 5890 33 14.Fig. 41

Fig. 39

Fig. 40

Fig. 41

DIAL STAND

DIAL

MASTER

22

FRONT AXLE - 4 X 4

Place proper thickness depth shim on pinion gear andinstall pinion rear bearing cone. Drive until it seatsagainst the throat face of pinion. Use dolley Pt. no.2704 5890 3316. Fig. 42

Fig. 42

Fig. 43

Fig. 44

Assemble bearing cone, slinger and new pinion sealinto housing using :

1] Installer, pinion oil seal Pt. no. 2698 5890 3513

2] Universal handle Pt. no. 2698 5890 3506. Fig. 43

Apply a light coat of oil to the lip of oil seal.

Install new collapsible spacer onto pinion stem andassemble into housing. Assemble end yoke, washerinto housing.

Note : Collapsible spacer should rest on bearing innerrace, and it can be fitted in any one direction.

Continue to tighten nut in small increments until therotating torque is achieved using Holder, yoke Pt. no.2698 5890 3505 and torque wrench. Fig. 44

23

FRONT AXLE - 4 X 4

Note : Tighten nut only enough to remove shaft endplay. Then continue to tighten nut in smallincrements until correct bearing preload torqueis attained. Exercise care during bearingpreload torque adjustment. DO NOTOVERTIGHTEN or loosen and then retightennut. Do not exceed bearing preload torque.

If exceeded, collapsible spacer will have tobe replaced. Bearing preload torque will haveto be readjusted again as per procedure.

Using a torque wrench, ensure that the rotating torqueof pinion is between 1.7 - 3.9 N.m. with new bearingsFig. 45

Clean & Assemble dummy differential bearingsPt. no. 2704 5890 3309 onto case. Fig. 46

Assemble differential case into carrier [without RingGear]

Mount dial guage and locate tip of indicator on flatsurface of case. Force the differential case as far aspossible in the direction towards dial guage.Fig. 47

With force still applied, set needle to zero (0).

Force differential assembly as far as it will go, inopposite direction. Repeat until the same reading isobtained. Record the reading. Fig. 48

This is the total amount of shims required. This ismeasurement A.

Fig. 46

Fig. 47

Fig. 48Fig. 45

24

FRONT AXLE - 4 X 4

Remove dial guage and differential assembly fromhousing.

Remove master bearings from differential case andset aside.

Assemble ring gear to case. Fig. 49

Note : Use new ring gear screws.

Draw up screws alternately and evenly. Torque ringgear screws to specification.

Assemble master bearings onto case.

Place differential assembly into housing. Install dialguage and locate tip of indicator on flat surface of oneof the ring gear screws.

Force differential case assembly away from piniongear. With force still applied to case, set needle at(0) zero. Fig. 50

Now push case assembly to the other side.

Force case assembly and ring gear to mesh with piniongear. Rock ring gear to allow teeth of gears to mesh.Take reading.

Repeat the exercise until same reading is obtained.

Record this as measurement B

Remove master bearings.

DIALINDICATOR

Fig. 49

Fig. 50

WORKSHEET FOR CALCULATING RING GEARBACKLASH AND DIFFERENTIAL BEARINGPRELOAD SHIMS.

1.Total amount of space Measurement A______measured without ring gear.

2.Total amount of space Measurement B______measured with gear set assembled in carrier.

3.Measurement A minus Measurement C______Measurement B dimensions.

Assemble shim pack using dimensions determined in A,B,C adjusting the packs as described below.

RING GEAR SIDE :

Assemble shim pack to measurement B - 0.125 mm. or B - 0.005"

OPPOSITE SIDE OF RING GEAR :

Assemble shim pack to measurement C. Add shim thickness 0.20 mm or 0.008" for differential bearing preloadand backlash.

RIN

G G

EA

R S

IDE

OP

PO

SIT

E R

ING

GE

AR

SID

E

25

FRONT AXLE - 4 X 4

Assemble required thickness of shims onto ring gearside and opposite side of case as determined usingDolley Pt.no. 2704 5890 3325. Fig. 51

Install spreader and indicator. Spread the carrier.Do not spread carrier over 0.5 mm. Fig. 52

Remove indicator.

Install differential assembly into carrier. Fig. 53

Install bearing caps. Fig. 54

Ensure correct fitment of caps by matching letters onbearing cap and carrier on both sides.

Torque bearing cap screws to specification.

Fig. 52

Fig. 53

Fig. 54Fig. 51

DIFFERENTIALHOUSING SPREADERDIAL INDICATOR

26

FRONT AXLE - 4 X 4

Check ring gear and pinion backlash at three equallyspaced points with dial guage. Fig. 55Backlash should be between 0.13 mm and 0.23 mm.Variation in back lash should not exceed 0.08 mmbetween 3 readings.High backlash is corrected by moving ring gear closerto pinion. Low backlash is corrected by moving ringgear away from pinion.These corrections are made by switching shims fromone side of differential case to other side.Note : If backlash is to specification, check gear and

pinion tooth contact pattern, and adjustaccordingly.

Refer procedure in rear Axle section for correcting toothcontact pattern.Install axle shafts through splines inside gear. Placethe snap ring in the shaft's groove. Fig. 56Assemble Cylindrical roller bearing in carrier housingusing Dolley Pt. no. 2704 5809 3306.Assemble oil seals using1 Installer pinion oil seal Pt. no. 2698 5890 35132) Handle universal Pt. no. 2698 5890 3506.Install mounting brackets on either side and torquebolts as specified. Replace brackets if necessary.Fig. 57Note : Brackets on LH and RH sides are not

interchangable.Apply liquid gasket (Anabond 676) to cover platesurface. Fig. 58The bead must be 1/8 to 1/4 inch in height and width.Tighten cover screws evenly to a torque of 38-45 N.m.Allow one hour curing time before vehicle operation.

Fill specified oil after curing.

Fig. 56

Fig. 57

Fig. 58Fig. 55

CONTOUR OFBEAD

DIAL INDICATORWITH BRACKETRY

RING GEAR

27

FRONT AXLE - 4 X 4

CONSTANT VELOCITY SHAFTS

Introduction :

Fixed Rzeppa Joint Fig. 59

Rzeppa joints are built with outer race, inner race,cage & six balls. Outer race & inner race have sphericalball grooves. Cage is assembled first with inner race /six balls and then outer race is assembled. Torque istransferred from inner race to outer race through sixballs.

Plunging Double offset (DOJ) Joint Fig. 60

DOJ is similar to Rzeppa joint, except for outer racewhich has straight & longer ball grooves, instead ofspherical grooves as in case of Rzeppa joint. Innerrace & cage can slide in and out on six balls tocompensate change in length of CV shafts.

Constant velocity joints used on both RH side andLH side are same, but for the difference in male &female splines at DOJ end.

RH half shaft has male splines on DOJ side and it fitsin side gear in differential case. Fig. 61

LH half shaft has female splines and it fits on axleshaft. Fig. 62

Fix Rzeppa joints are used at wheel end.

Double offset joints are used at centre section.

Fig. 60

Fig. 61

Fig. 62Fig. 59

Left hand side

Right hand side

Plunging Double Offset Joint

Fixed Rzeppa Joint

28

FRONT AXLE - 4 X 4

TOOLS FOR CV JOINT ASSEMBLY

Fig. 63

1. Plain plier, snap ring. Pt. no. 2704 5890 3330

2. Tang plier : snap ring Pt. no. 2704 5890 3331

3. Clamp crimper Pt. no. 2704 5890 3332

4. Ball assembly Pt. no. 2704 5890 3333

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY RZEPPA CV JOINT

Mark the position of small end of the boot on shaft. Ithas be fitted back in the same position duringreassembly Fig. 64

Fig. 64

29

FRONT AXLE - 4 X 4

Cut boot clamps & discard. Fig. 65

Cut boots and discard. Fig. 66

Boot clamps and boots are not to be reused.

Wipe away grease, to make snap ring of inner racevisible.

Expand snap ring and remove shaft by tapping onouter race by brass hammer.

Place the CV joint in vice

Note : Use soft Teflon V-jaws, to prevent damage tosplines.

Mount Ball assembly tool Pt. no. 2704 5890 3333.Fig. 67

Fig. 65

Fig. 66

Fig. 67

30

FRONT AXLE - 4 X 4

Using Ball assembly tool tilt inner race from side toside in star pattern and remove all balls from cage.Fig. 68

Pivot cage and remove inner race assembly from outerrace. Fig. 69

Pivot Inner Race and remove from cage. Fig. 70

Note : Mark positions of inner race, cage & ballsbefore dismantling. Same position to beretained during reassembly.

REASSEMBLY RZEPPA CV JOINT

Clean CV joint components and boot area on shaftsusing approved solvents. Do not use gasoline.

Apply tape to shaft splines to protect boot duringinstallation.

Slide new small clamp and boot on one side of shafthaving one Circlip groove. Do not tighten shaft at thistime.

Lightly coat inner and outer race with approved Lithiumgrease. To reassemble joint, follow the procedure inreverse for disassembly.

Install new circlip in inner race.

Pack CV joint only with specified grease. If there isany remaining grease, place it inside the boot.

Align CV joint splines with shaft splines. Gently rockCV joint while pushing onto shaft, until click is heard.Pull firmly on CV joint to make sure circlip is seated.

NOTE : If necessary, tap CV joint shaft with brass orsoft face mallet.

Position the boot and clamp over CV joint (large end)and secure with appropriate clamp.Use Clamp climper Pt. no. 2704 5890 3332.

Insert blunt screw driver between shaft and small endof boot to equalize air. Align boot marks on shaft. Installand tighten small clamp.

Fig. 68

Fig. 69

Fig. 70

31

FRONT AXLE - 4 X 4

DISASSEMBLY PLUNGING DOUBLE OFFSET CVJOINT

Mark position of boot. It has to be assembled in sameposition during reassembly.

Cut and discard boot clamp.

Cut and discard boot.

Inspect Grease for contamination.

Note : If grease is contaminated CV joint needs toreplaced.

Wipe away excess grease to access retainer ring inouter race.

Remove retainer ring, using a screw driver. Fig. 71

Remove Outer Race.

Using tang snap ring plier, Pt. no. 2704 5890 3331expand and slide back inside circlip. Fig. 72

Remove outer circlip using plain snap ring Pt. no. 27045890 3330. Fig. 73

Remove inner race assembly from shaft.

If required, use a soft mallet.

By slight tapping, remove balls from inner race.

Pivot inner race and remove from cage. Fig. 74

Fig. 72

Fig. 73

Fig. 74Fig. 71

32

FRONT AXLE - 4 X 4

ASSEMBLY PLUNGING DOUBLE OFFSET CVJOINT

Clean CV joint components using approved solvent.

Apply tape to protect boot during installation.

Slide new small clamp and boot on the side of shafthaving two Circlip grooves. Do not tighten clamp at-this time.

Assemble inner race, cage and ball assembly.

Install Inner race assembly and two types of newcirclips on shaft.

Pack approximately with 2/3th of grease in outer race.

Place remaining grease inside boot.

Install outer race assembly over ball and cageassembly.

Push back inner race with balls & install large retainingring.

Position boot and clamp over CV joint using Clampcrimper Pt. no. 2704 5890 3332.

Align boot marks on shafts and tighten small clamps.

INSTALLATION OF CV JOINT SHAFT ON VEHICLE.

Refer the section of removal from vehicle for guidelines.

Holding axle shaft assembly with both hands at CVjoints, insert axle shaft assembly into differential sidegear.

Note : Ensure that oil seal is not cut or nicked inabove process.

Push the shaft in to place until a click is heard or abump is felt as the snap ring engages the end of sidegear.

Holding shaft assembly with one hand at outboardCV joint, attach supporting wire.

Assemble steering knuckles to ball joint studs.Assemble nuts at top and bottom and torque tospecification.

CV JOINT FAILURE ANALYSIS

Most common cause of CV joint failure is due to bootfailure. While inspecting boots, it is important toobserve the boot for any missing portion, cracks, andholes. These defects will allow water, dirt to enter joint,as well as loss of lubrication. If this occurs, shaft mustbe disassembled and inspected for damage to internalcomponents.

TROUBLE SHOOTING - AXLE

Most drive axle problems fall into the categories ofnoise, vibration, leaks and failure to transmit power.Problem diagnosis begins with customer's complaint,which includes exact description of the type of noiseor vibration and when it occurs.

This is to be followed by a road test over various typesof road surfaces and speeds where complaint occurs.This helps to locate the fault area and to eliminate it.

33

FRONT AXLE - 4 X 4

CONDITION POSSIBLE CAUSES

Noise in all driving modes Road and tires, wheel bearings

Noise changes with type of road surface Road and tires

Noise tone lowers with vehicle speed Tires

Noise increase on turns Differential pinion and side gears, axle wheel bearings

Noise in one or more driving modes Ring and pinion gears

Clunk on change of speed or Worn differential shaft or thrust washers ,worn U-jointsdirection of power flow

Wheel noise Wheel loose; faulty or bad wheel bearing

Vibration Damaged drive shaft, missing drive shaft balance weight,worn or out-of-balance wheels, loose wheel nuts, worn U-joints, loose/broken spring, damaged axle shaft bearings,loose pinion gear nut, excessive pinion yoke run out, bentaxle shaft.

Differential gears scored Insufficient lubrication, improper grade of lubricant,lubricant contamination, excessive spinning of wheels.

Loss of lubricant Lubricant level too high, worn axle shaft seals, crackeddifferential housing, worn drive pinion gear shaft seal,scored and worn yoke, axle cover not properly sealed,plugged vent or vent tube.

Axle overheating Lubricant level too low, incorrect grade of lubricant,contaminated lubricant, bearing preload too high,excessive gear wear, insufficient ring gear backlash.

Gear teeth broken Overloading, erratic clutch operating, wheel spinning,improper adjustment

Axle gear noise Insufficient lubricant, incorrect backlash, improper toothcontact, worn/damaged gears

Axle noise Insufficient lubricant, improper ring gear and drive piniongear adjustment, unmatched ring gear and drive piniongear, worn teeth on ring gear or drive pinion gear, Loosedrive pinion gear shaft bearings, loose differentialbearings, misaligned ring and pinion gear, loose differentialbearing capscrews, worn bearings.

34

FRONT AXLE - 4 X 4

Automatic Locking Hub (Model : 1704-000-002) of Divgi Warner Limited

Introduction

Automatic Hub Locks Model : 1704-000-002 of Divgi Warner Limited is presently used on Telcoline 4x4vehicles.

When 4-wheel drive is selected, automatic hub, locks axle shaft to wheel hub. This occurs when vehicle isdriven in either forward or reverse direction. Hub unlocks when 2-wheel drive is selected, and vehicle is drivenin opposite direction for a few feet.

D

Fig. 75 Construction & operation

Construction

The 4 Tanged washer is held in place on the Wheel Spindle. The cut-outs on the drag sleeve(26) fit over thetangs on the washer, preventing the drag sleeve from rotating. The brake band (24) fits over the serratedportion of the drag sleeve. The tangs of the brake band are fitted through the window in the steel inner cage(21). The plastic outer cage (20) fits over the inner cage. Each tang of the brake band fits through eachcutout in the outer cage. The cam follower (19) is attached to the clutch gear (15). The follower profile on thecam follower (A) ride against the cam faces or ramps of the steel inner cage. The clutch gear slides on thesplines on the out side the hub sleeve (16). The axle shaft(C) is splined to the inside of the hub sleeve. Thelarge teeth on the outside of the clutch gear can engage the teeth inside the outer clutch housing (9).Theouter clutch housing is bolted to the wheel hub. An End Cap (2) fits over the hub lock assembly. The endcap contains a bearing assembly (6) that supports the other end of the hub sleeve. The End Cap is fittedwith an Aluminium Decorative Plate(1) for better aesthetics.

35

FRONT AXLE - 4 X 4

Operational Summary

Briefly, this is what happens when the hub locks,

The clutch gear (15) and cam follower (19) rotateup the cam face of the inner cage (21). Thiscauses the clutch gear to move outward on thehub sleeve (16). The out side teeth of the clutchgear engage the inside teeth of the outer clutchhousing (9), locking the wheel hub to the axleshaft.

When the hub un-locks,

The clutch gear and cam follower rotate in theopposite direction, back down the cam face of theinner cage. Spring pressure forces the clutch gearinward, unlocking the wheel hub from the axleshaft.

Operation

Now, let’s examine how the hub operates in detail.When 4-wheel drive is engaged (and vehicle startsto move ), the axle shaft starts to turn the hubsleeve (16), clutch gear (15) and cam follower (19).The steel inner cage (21) and plastic outer cage(20) also start to turn. (Remember, the drag sleeve(26) is fixed to the wheel spindle and doesn’trotate) When the inner cage window hits the firstbrake band tang (30) the band tightens up on thedrag sleeve. This stops the inner cage. The camfollower (19) is forced up the ramp of the innercage (21).

As the cam follower moves up the ramp of theinner cage, it is moved outward along the hubsleeve (16), pushing the clutch gear (15) intoengagement with the outer clutch housing. The camfollower (19) also pushes against the lugs of theouter cage (20). The outer cage tang contacts thesecond brake band tang (30). This unlocks thebrake band and allows it to turn freely on the dragsleeve serration’s.

When 2-wheel drive is selected to disengage thehubs, and the vehicle is driven in the oppositedirection for a few feet, the rotating front wheelturns the outer clutch housing, clutch gear (15) andcam follower (19) in the opposite direction. The camfollower moves down the ramp of the inner cage(20). The return spring (14) pushes the clutch gear(15) along the hub sleeve (16) and out ofengagement with the outer clutch housing.

Fig. 76

Fig. 77

36

FRONT AXLE - 4 X 4

SPECIFICATIONS :

Input Configuration Female Splines

Output Configuration Bolted Flange(M10 X 25MM, 6Nos.Bolts)

Location 74 mm dia and ‘O’ Ring for water resistance

Working Principle Automatic Locking.

Projected Length over from the 74.0 mm ( Nom. )face of the wheel hub

Lubricant :

Drag sleeve - Darmex 123 LT grease (2 to 4 gms.)

Assly. Cam and Follower - Castrol ATF- TQ

Assly. Bearing race - Light wheel Bearing grease(Castrol LCG –2 OR Darmex 123 LT grease) (2 to 5 gms.)

Locking & Unlocking in degree. 90 Deg. (Clockwise & Counter clockwise)

Gross Weight 1.75 Kgs. Approx.

Appearance Black Powder Coated withAluminium Decorative Plate

37

FRONT AXLE - 4 X 4

3.1

NOTE : In this diagnosis section, there are somenumerical call-outs (such as (1), (2) etc.). For thesecall-outs refer to the drawing on page - 3

Oil Leaks

Make sure that a suspected oil leak is actuallycoming from the hub. Oil leaks can originate in theaxle shaft (oil seal).

An oil leak from the hub can be caused by :

1. A cracked or porous or improper fitment ofprotective end cap

2. Damaged or missing “O” rings.3. Incorrectly installed or damaged sealing ring

(10) between the End Cap and outer clutchhousing and wheel hub.

Does not Engage or Disengage

Before disassembly of a locking hub, be sure theproblem is caused by the hub and not anothercomponent in the drive train.Other possible problems include :

· Transfer case not engaging or disengaging frontaxle shaft.

· Viscosity of front differential lubricant too high(i.e. due to cold weather).

· Front differential pre-load too high.· Seized front axle shaft bearing.

3.2

IMPORTANT : When diagnosing a “ratcheting” hub,remember that the noisy hub is “NOT” always thedefective one. It depends up on whether the hubshave just been disengaged. Let’s examine why.

If only one hub disengages after 2-wheel drive isselected, the faulty hub transmits the wheel rotationto the axle shaft. The mechanical situation is likea conventional axle raised off the ground. The axleshaft drives the differential pinions through theside gear. The ring gear and cage are not turning,so the other side gear and axle shaft are driven in

the opposite direction to the first one. The axleshaft tries to engage the hub against the directionof the wheel rotation, causing the noise from thehub. In this case, the faulty hub is not making thenoise. The non-noisy hub should be checked. If 4-wheel drive is selected and only one hub engages,there may not be any noise from the hub,depending on the malfunction. The only symptommight be a loss of drive at that hub. If the hub is“ratcheting” in 4-wheel drive, it should be inspected.

Possible Causes

A broken or missing 4 tanged washer can causeproblems in 2- or 4- wheel drive.

A broken or missing washer will allow the dragsleeve to rotate with the brake band . If the hubare not engaged , the brake band is unable to lockon the drag sleeve and initiate the locking actionof the clutches. If the hubs are engaged, the brakeband can not be released to allow the clutch gearto disengage.

A broken or missing brake band (24) cannot lockthe inner cage to engage the hub or be unlockedby the outer sleeve to allow the clutch gear todisengage.

If both brake band tangs are touching the centerpost of the outer sleeve, there cannot be properlocking or unlocking action of the brake bandthrough the movement of the inner cage (21) andouter cage (20). The center post of the outer cageand the window of the inner cage move relative toeach other when the hub is locking or unlocking. Ifthe cages are not rotating freely over each other,the hub may fail to engage or disengage.

A sticking clutch gear can cause the hub to bindin either the engage or the disengage position. Abroken return spring will cause the hub to remainin the engaged position.

In each case, the defective component should bereplaced with the correct part or assembly. Alwayscheck the most recent parts list for the correct partnumbers and available assemblies for the type ofthe hub you are servicing.

DIAGNOSIS

38

FRONT AXLE - 4 X 4

4.1 AUTOMATIC LOCKING HUB DIS-ASSEMBLY

1. Remove the end cap and bearing race spring(4). Remove the bearing inner race andretainer(5). Note the position of thecomponents for correct assembly.

2. Remove 6 nos. bolts of auto locking hub.

3. And pull out the hub assembly.

DIS-ASSEMBLY & INSPECTION

4. To make disassembly easier, install hubassembly on the stand, so that the entireassembly can be positioned vertically.

5. Remove the snap ring (27) with suitable plier.Exercise caution when removing the snap ring.

6. Remove the drag sleeve, with brake band(26).To lift out the drag sleeve, rotate it slightly torelease the brake band tangs from the sleevesand tilt it up on the side opposite the tangs.

7. The clip doesn’t need to be removed for thenormal servicing. However, if it’s damaged,remove it using thumbnail force only to avoidstretching or distorting it. Do not remove thebrake band for normal servicing.

8. Remove the large snap ring from the outerclutch housing.

Fig. 78

Fig. 79

Fig. 80

39

FRONT AXLE - 4 X 4

9. Remove the steel inner cage (21) by pressingit over the tang of the outer cage (20) (in thewindow). Lift the inner cage straight out, don’ttilt it.

10. Remove the plastic outer cage by prying onelug out of the large groove in the outer clutchhousing. Hold the lug and go on to the nextone. It’s easiest to start with the lugs oppositethe one that fits into the window of the steelinner cage.

11. Invert the entire hub and slide the cam &follower assembly out of the outer clutchhousing.

4.2 Inspection

● Examine the protective end cap (2) for cracks,O - ring(3).

● Brake band (24) for damage or distortion.

● Also, inspect the teeth on the cam follower,clutch gear and outer clutch housing for wearor damage.

● Not all components are replaceable separately.

Fig. 81

Fig. 82

40

FRONT AXLE - 4 X 4

LUBRICATION AND ASSEMBLY

5.1 Lubrication

The automatic hub lock should be lubricatedafter every 24,000 miles.

1. Remove drag sleeve assembly and keepaside, DO NOT lubricate drag sleeveassembly as it is permanently lubricatedwith Darmex grease.

2. Check the brake band and drag sleeveserration for presence of appropriate quantity ofgrease and wear, in case of insufficientgrease, replace the drag sleeve.

3. DO NOT remove the brake band as this couldchange the spring tension and affect huboperation.

4. All components except drag sleeve assemblyand outer bearing race assembly are lubricatedby dipping them in automatic transmissionfluid. Allow excess fluid to drip off beforeassembling the hub.

5. Lubricate the outer bearing race with light wheelbearing grease. DO NOT use axle grease.

5.2 Assembly

1. Install the hub sleeve and return springinto the outer clutch housing from the inside.

2. Install the plastic outer cage (21) into the largegroove in the outer clutch housing (9). Thecage may be easier to install if the tangs onthe each side of the cutout are installed first.

3. Install the steel inner cage (20) inside theplastic outer cage (21). (For clarity, the cageson the right are shown outside the hub.) Thewindow (A) must engage the tang (B) of theouter cage for correct positioning.

Note: After installation, the V-shaped cutout in bothcages must ride over the tangs of the cam follower. Fig. 83

41

FRONT AXLE - 4 X 4

4. Install the large snap ring in the top groove ofthe outer clutch housing.

6. Install the drag sleeve assembly in the innercage, so that the tangs of the brake band arelocated on each side of the outer cage tang(C)and in the window of the inner cage. Tilt thedrag sleeve slightly to engage the tangs, butbe careful not to cock the hub sleeve.

7. Install the snap ring (27) to the hub sleeve.

8. Install the outer bearing assembly, with theretainer and bearing facing the interior of thehub and the cap facing out.

9. Install the cap with the bearing race spring.

10. Ensure that the ALH is in ‘Unlock ‘ mode whileinstalling on the wheel hub.

C

Fig. 84

Fig. 85

42

FRONT AXLE - 4 X 4

11. Push the hub partway into the wheel, makingsure cutouts in the drag sleeve are aligned withthe tangs of the four tang washer (D). Installthe bolts on the hub.

12. Tight the end cap with the help of pin spanner.

Torque for M-10 X 25mm Bolt is 6 Kgm.

Fig. 86

Fig. 87

Fig. 88

43

FRONT AXLE - 4 X 4

PARTS LIST OF SERVICEABLE ITEMS (EXPLODED VIEW)

SR. NO. PART NAME QTY/ HUB

1 END CAP WITH DECAIL PLATE. 12 SPRING, BEARING RACE 13 ASSY. BEARING 14 BOLT (M 10 X 1.5 X 25mm) 65 OUTER CLUTCH HSG. 16 ‘O’ RING (OCH) 17 ASSLY. CAM AND FOLLOWER 18 CAGE OUTER 19 CAGE INNER 110 ASSY., DRAG SLEEVE 111 RING, RETAINER 112 RING, RETAINER 113 “O” RING (Cover) 1

SERVICE TOOLS

Sr. No. Tool Description. Tool No. Size

1 Torque wrench Standard 10-50 lbft2 Work holding tool T-10101-A3 Screw driver Standard 9”4 Hex. Socket Standard 13 mm5 Pin spanner T-100686 External circlip plier Standard 8”7 Special Allen for M-10 Bolt T-100998 Lock-Unlock fixture F- 10240

Fig. 89

44

FRONT AXLE - 4 X 4

Fig. 90

NOTE : This assembly was used earlier (Beforeintroduction of Divgi Warner AutomaticLocking Hub). This assembly is non -serviceable. If it is established that there ismalfunctioning, the unit has to be replacedwith automatic hub lock of Divgi Warner Ltd.

2 - TF - WAY LOCK FREE RUNNING HUB (IF FITTED)(PART NO. : 2667 3375 0105)

Procedure for replacing TF hub lock with Divgi Warnerhub lock is given in page 48.

The construction is shown only for the purpose ofunderstanding its functioning.

45

FRONT AXLE - 4 X 4

Fig. 91

Fig. 92

Fig. 93

LOCK

AU

TO

LOCK

REMOVAL & INSTALLATION OF FREE RUNNINGHUB ON VEHICLE

Removal :

Set the knob to "Lock" Fig. 91

Remove free - running hub main body assembly afterremoving fixing bolts.

Remove spindle washer and brake set after removingsnap ring from drive shaft. Fig. 92

Note : The drive shaft will become free after removingthe snap ring. Take care to support it suitably.

Installation :

Install brake set to spindle. Install snap ring tominimize drive shaft axial end play. Fig. 92

Note : Allowable drive shaft axial end play to 0.2 mmor less.

Confirm the knob to lock position.

Install free - running hub main body assembly afteraligning position of release plate and wire brake sothat the end portion of wire brake does not overlapprotruded portion of release plate. Fig. 93

46

FRONT AXLE - 4 X 4

Fig. 94

Fig. 95

LOCK

AU

TO

AU

TO

LOCK

LOCK

LOCK

AUTO

AUTO

Make sure that the free - running hub is installedcorrectly by pushing it lightly by hand. If there is someclearance between wheel hub and free - running hubhousing, reinstall it. Fig.94

After free - running hub is installed correctly, tightenbolts to specified torque.

After installation, set knobs on both sides to Auto,then release hub from Lock position by moving loadedwheels forward and backward when drive shafts arestationery. Fig. 95

The reason for above manoeuvre is that the differencein the lock and free position from other side whichmight cause differential carrier gear noise.

47

FRONT AXLE - 4 X 4

SOLUTION TO NOISE PROBLEM IN 4X2 MODE(Pertaining to hub lock)

Driving in 4x2 mode

Noise No Noise

Shift to 4 H OK

No NoiseNoise

Report to the Dealer


Reverser the vehicle in 4H mode only,for 6 to 8 feet. Then shif to 2H mode anddrive in the forward direction

OK

No NoiseNoise


48

FRONT AXLE - 4 X 4

Checks before following the procedure :

Disengage the Hub Locks by shifting the vehiclein “2H” mode. Make sure that the hand brake is“Engaged”.

Fig. 96

Fig. 97

Fig. 98 Fig. 99

2. Turn the “Knob” on the Tochigi-Fuji Hub Lock to“Lock” with a 21 mm socket & ratchet.

3. Remove 6 bolts with a std. 8 mm Allen key orSpl. Allen key T-10099. Take out the Hub fromWheel.

4. Remove the axle circlip with 12” Ext. circlipplier. Take out the circlip, Tochigi-Fuji spacerand Brake Set assembly.

1. Remove the Hub Cap from the Wheel.

PROCEDURE FOR REMOVAL OF T.F. (2667 3375 01 05) HUB LOCK & INSTALLATIONOF INDIGENOUS DIVGI-WARNER “1704” HUB LOCK

49

FRONT AXLE - 4 X 4

Fig. 100

Fig. 101

5. Install the new spacer (for 1704 ALH) on theaxle and re-install the axle circlip in the axlegroove.

6. Install the “1704” Hub Lock in the wheel hub.Make sure that the slots on the Drag Sleeveare engaging with the 4 tanged washer.

Fig. 102

Fig. 103

7. Rotate the Hub Lock to match the threadedholes & holes on the flange of the Hub Lock.

8. Tighten 6 “1704” bolts with Spl. Allen key T-10099 to approx. 6 kg-m torque using TorqueWrench.

9. Ensure proper tightening of the bolts. Install thehub cap on the wheel to complete theinstallation.

Fig. 104

50

FRONT AXLE - 4 X 4NOTES

1

REAR AXLE

REAR AXLE

3

REAR AXLE

INTRODUCTION :Rear axle of Telcoline has unique features ofunitised bearings.

Unitised bearings are pre-set and require noadjustments. Lubrication is through differential lubeand draining of axle lube is not required to servicehub bearing or seal.

Vehicles with 4x4 arrangement are equipped withTrack - Lok limited slip differential. We haveintroduced limited slip differential in 4x2 faceliftvehicles also (100% fitment). This system is similarto conventional differential, except that part oftorque from ring gear is transmitted through clutchpacks between side gears and differential case. Incase of wheel slippage clutch pack opposite toslipping side, is activated by separating forcesbetween pinion mate and corresponding side gear.This increases torque delivered to non slippingwheel and vehicle begins to move.

It is important to recognize that if, with unequaltraction, both wheels slip, the Track - Lok has doneall it can possibly do.

5

REAR AXLE

CONTENTS :


1. Exploded view 7

2. Specification & service data 8

3. Special tools list 9

4. Removal from vehicle 10

5. Disassembly :

(i) Unitised bearing 12

(ii) Carrier centre section 13

(iii) Drive pinion 17

6. Cleaning and inspection 18

7. Assembly

a) Unitised bearing 20

b) Pinion bearing cup 24

c) Carrier centre section 26

d) Differential 29

8. Interpretation of tooth contact pattern 32

9. Measuring axle end play 34


Note : For Rear Axle without limited slip differential, refer to Front Axle section for guidelines.

7

REAR AXLE

CONSTRUCTION :

Fig. 1

LIMITED SLIP DIFFERENTIAL

8

REAR AXLE

SPECIFICATION & SERVICE DATA :

Type : Single reduction, salisbury type with hypoid gears and semi floating axle shafts.

Vehicles with 4x4 arrangement are provided with Limited slip differential .

Limited slip differential has been introduced in 4x2 face lift version also.

Axle Ratio : 44/9

Weight of Axle : 115 kg.

Quantity of Oil : 2.2 Liters

Tightening Torque

Cover Screws : 38 - 45 Nm

Filling plug : 20 - 35 Nm

Drain Plug : 20 - 35 Nm

Differential Bearing caps screws : 95 - 122 Nm

Brake Backing plate nut : 37 - 55 Nm

Ring Gears Screws : 95 - 122 Nm

Drive pinion nut : 220 - 680 Nm

Lubrication

Centre Housing : 2.2 Liters

Type of oil : Multigrade oil conforming to SAE 85W140 API GL5specifications.

* Friction modifier 40819 (2-5%) to be added to oil forrear axle with limited slip differential.

Lubricant change interval : 40000 kms / 24000 miles of vehicle running.

Grease for rear Hub (Only at the : 25 gm each, lithium base multipurpose EP2time of assembly)

Pinion Bearing Pre load

Torque to rotate drive pinion only : 2.26 - 4.52 Nm

Differential Assembly

Ring gear to pinion gear Backlash : 0.13 - 0.20 mm

Maximum permissible variation between : 0.08 mmchecked points.

Pre load of Differential side bearing : 0.07 to 0.20 mm

Axle End Play

Permissible axle end play : 0.025 mm to 0.38 mm max.

9

REAR AXLE



1. Adapter plug, differential hub : 2698 5890 3501

2. Adapter, differential bearing cone : 2698 5890 3502

3. Adapter, rear pinion bearing cone : 2698 5890 3503

4. Remover, Yoke : 2698 5890 3504

5. Holder, yoke : 2698 5890 3505

6. Handle universal : 2698 5890 3506

7. Puller Slide Hammer : 2698 5890 3507

8. Installer, front pinion bearing cup : 2698 5890 3508

9. Installer, rear pinion bearing cup : 2698 5890 3509

10. Remover, front pinion bearing cup : 2698 5890 3510

11. Remover, rear pinion bearing cup : 2698 5890 3511

12. Installer, differential side bearing : 2698 5890 3512

13. Installer, pinion oil seal : 2698 5890 3513

14. Master Bearing differential : 2698 5890 3514

15. Press : 2698 5890 3515

16. Adapter ring : 2698 5890 3516

17. Spreader axle housing : 2698 5890 3517

18. Installer, yoke : 2698 5890 3518

19. Installer, rear pinion bearing cone : 2698 5890 3519

20. Pinion Height set (Includes Master 2698 5890 3520block, Pinion height gauge) :

21. Bearing Puller for Axle shaft : 2698 5890 3521

22. Drive square for drain plug : 2654 5890 3524

Carrier with Limited slip differential

23. Track lock tool : 2698 5890 3501(Includes 2 adapter, 1 driving bar)

10

REAR AXLE

REMOVAL FROM VEHICLE

Place wheel chocks on front wheel.

Drain oil from rear axle while it is hot. Use Drivesquare Pt. no. 2654 5890 3524 for loosening drainplug.

Disconnect propeller shaft from tail pinion and layit on side.

Unscrew and remove nuts and bolts connecting endof shock absorber to the bracket on rear axle (iffitted).

Unscrew and remove bolts and nuts holding antirollbar to rear axle (if fitted).

Disconnect rear brake hose from bracket onchassis frame after removing lock clip. Removebrake bundy pipe from wheel cylinder and keep itsafely. Plug the opening to avoid oil flow and entryof dirt.

Slightly loosen wheel nuts and lift rear axleassembly by jacks placed under axle tube nearspring seat.

Caution : Do not place jack under rear axle centrehousing but only on axle tube especiallyon a loaded vehicle.

Place suitable supports below long members.

Remove wheel nuts and take out wheels.

Release brake shoes by turning brake adjustingcams until brake drum rotates freely.

Remove brake drums. Use two bolts M10 X 1.0 X25 mm. Fig. 2

Remove spring clips holding parking brake cablewith anchor plate assembly.

Disconnect parking brake cable from lever onanchor plate assembly and pull out cable.

Supporting rear axle at centre by a trolly jack, drawout axle assembly. Mount it on workstand.

WARNING:

A serious or fatal injury can occur if vehicleis not properly jacked.

Exercise extreme care when working oncomponents utilizing snap rings or springloaded retention devices.

Fig. 2

11

REAR AXLE

DISASSEMBLY OF REAR AXLE

Unitised wheel bearing lubrication is from hypoidgear lube, thus it is without grease seal. Fig. 3

Unscrew and remove anchor plate nuts, holdinganchor plates to axle housing. Fig. 4

Note : Discard nuts, replace with new ones duringassembly.

Remove axle shafts. Fig. 5

Note : While removing axle shafts make sure thatthey are marked properly (LH & RH). Incase bearing cups also are needed to beremoved from axle housing, tie them withrespective axle shafts.

Bearing cups & wheel bearings areprematched. In case they are interchanged,performance wheel bearings may getaffected.

Fig. 3

Fig. 4

Fig. 5

12

REAR AXLE

To remove bearing cup, use Puller slide hammer Pt.No. 2698 5890 3507. Fig. 6

Removal of Unitised bearing.

Remove snap ring from axle shaft.

Clamp axle shaft in a vice. Drill a 6.5 mm hole todepth of 5 mm in retainer ring. Fig. 7

Caution : Drill can damage axle shaft if usednegligently.

Use chisel and strike sharply to break retainer ring.Fig. 8

Note : Discard retainer ring. Use new one duringassembly.

Push retainer plate and seal towards flange of axleshaft.

Use Bearing Puller for Axle shaft Pt. no. 2698 58903521.

Install flange plate (Pt. no. xxxxxxxxxxxxxxx) to flangeof axle shaft.

Install bolts into flange plate. Slide forcing plate overaxle shaft. Install adapters so that they seat undercup rib ring.

Gradually tighten bolts until bearing cone is removed.Fig. 9

Caution : Do not heat or cut bearing cone assembly.

Remove seal and retainer plate. Discard Seal. Discardretainer plate, if found distorted.

Fig. 7

Fig. 8

Fig. 9Fig. 6

13

REAR AXLE

Remove cover plate screws & cover plate. Fig 10

Disassembly of Carrier Center Section.

Note: Liquid gasket is used to seal cover plate.Scrape and clear it.

Remove bearing caps. Fig 11

Note :Mating letters are stamped on caps and car-rier on either side. It is essential to match let-ters on both sides.

Mount spreader Pt. No. 2698 5890 3517 to housing.Do not spread carrier more than 0.58 mm. Use dialgauge. Fig 12

Pry out differential case from carrier. Fig 13

Remove spreader.

Fig. 11

Fig. 12

Fig. 10 Fig. 13

14

REAR AXLE

Remove side bearing cone from differential case usingspecial tools given below:

1. Adapter, differential bearing cone Pt. no. 2698 5890 3502

2. Adapter plug, differential hub Pt. no. 2698 5090 3501

3. Adapter ring Pt. no. 2698 5890 3516. Fig. 14

Identify shims and side bearings on both sides. Theyare not to be interchanged during assembly.

If shims are damaged, replace with new shims duringassembly.

Reposition case in puller and remove side bearing coneon the other side in same manner.

Note : It is always preferred to replace side bearingsonce pulled out. But one can confirm free rollingof bearings and reuse it, if they are defect free.

Remove ring gear screws. Fig. 15

Remove ring gear.

If required tap ring gear with a mallet to free it fromcase. Fig. 16

Note: Discard ring gear screws and replace withnew ones.

Clamp any one of axle shafts in vice firmly. Fig. 17

Caution: Vice jaws should not locate on axle splinesor any machined surfaces.

Install differential case on axle shaft.

Fig. 14 Fig. 17

Fig. 16

Fig. 15

Press

Adapter

Adapter Ring

15

REAR AXLE

Use a suitable drift to remove the roll pin retainingcross shaft. Fig. 18

Use hammer and punch as shown to remove thecross pin from case. Fig. 19

Install adapter plate of track lock tool Pt. no. 26995890 3501 into bottom side gear. Apply a smallamount of grease to centering hole of adapter plate.Fig. 20

Install threaded adapter of track lock tool into topside gear.

Screw into threaded adapter until it is centered intoadapter plate. Use small screw driver to preventadapter from turning. Fig. 21

Fig. 19

Fig. 20

Fig. 21Fig. 18

16

REAR AXLE

Apply torque to driving bar of track lock tool tocollapse belleville plates.

Remove both pinion mate spherical washers.

Use a shim stock of 0.76 mm thickness or anequivalent tool to push out spherical washers. Fig.22

Relieve tension of belleville plates by looseningdriving bar.

Suitably rotate pinion mate gears and take themout. Fig. 23

Hold top clutch pack with one hand & removetools.

Remove top side gear and clutch pack. Fig. 24

Note: Keep the pack of plates and discs intact inexactly the same position.

Remove the case from axle shaft. Turn case withring gear side up and remove thrust washer, sidegear and clutch pack. Fig. 25

Remove retainer clips and allow separation ofplates and discs.

Fig. 22 Fig. 25

Fig. 24

Fig. 23

17

REAR AXLE

Note :Keep the pack of plates and discs exactlyas they were removed.

Drive Pinion Removal

Remove end yoke using tools given below :

1. Holder Pt. No. 2698 5890 3505

2. Remover, yoke Pt. no. 2698 5890 3504. Fig. 26

If yoke or flange shows wear in the area of sealcontact, it should be replaced.

Remove pinion by tapping with mallet. Hold thepinion with hand to avoid it's fall. Fig. 27

Caution : Gear teeth have sharp edges. Handlegears carefully to avoid injury. Fig. 27

Collect shims and keep them together. Replaceshims if found damaged.

Note : Discard collapsible spacer. New one to beused during assembly.

Pull out pinion oil seal with puller slide hammerPt. No. 2698 5890 3507. Fig. 28

Note : Discard oil seal

Remove bearing cone and outer thrust washer.

Turn nose of carrier down. Remove outer pinionbearing cup using tools given below :

1. Remover front pinion bearing cup Pt. No. 26985890 3510

2. Handle Pt. No. 2698 5890 3506. Fig. 29

Fig. 27

Fig. 28

Fig. 29Fig. 26

18

REAR AXLE

Fig. 31

Fig. 30

Turn nose of carrier up and remove inner pinionbearing cup using tools given below :

1. Remover rear pinion bearing cup. Pt. No. 26985890 3511

2. Handle Pt. No. 2698 5890 3506. Fig. 30

Note: Pinion depth shim is located between innerpinion bearing cone and pinion gear.

Remove inner pinion bearing using tools givenbelow:

1. Press Pt. No. 698 5890 3515

2. Adapter, rear pinion bearing cone. 2698 58903503

3. Adapter ring Pt. No. 2698 5890 3516. Fig. 31

Remove pinion depth shim from pinion.

CLEANING AND INSPECTION

Unitised Wheel Bearing

Clean bearing cup with metal cleaning solvent.Inspect cup for any possible wear, nicks etc.

Cone assembly can be cleaned in its installedposition on axle shaft.

Use stiff bristle brush and compressed air.

Note : Bearing should not be ‘Spin dried’ withcompressed air. Air should be directed sothat it goes through the bearing.

Clean bearing bore in housing.

Lubricate bearing with a small amount of specifiedlube during installation.

19

REAR AXLE

Fig.32

Fig. 33

Fig. 34

Carrier Centre Section

Inspect plates and discs for wear and scoring.Fig.32

Note : If any one member of either stock showsevidence of excessive wear or scoring,complete stock needs to be replaced onBOTH sides.

Inspect gear teeth of side gears and pinion mategears for wear and cracks.

Inspect external teeth of side gears for wear &crack.

Note : If replacement of one gear is required, thenBOTH side gears, pinion mate gears andwashers are to be replaced.

Inspect cross pin for excessive wear. Replace ifnecessary.

Inspect for wear on clutch retainer clips.

Note : Replace all four clips if wear is evident onany one of retainer clips.

Inspect differential case for scoring, wear or metalpick up. If noticed on machined surfaces, thencase needs to be replaced.

Pre lubricate thrust face of side gears & plates /discs. Fig. 33

Note : Plates and discs to be assembled in thereverse sequence for removal Fig. 34

20

REAR AXLE

Fig. 35

ASSEMBLY

INSTALLATION OF UNITISED BEARING

Note : Apply grease by hand before assembly(Lithium Base Multipurpose EP2) onunitised bearing. Minimum quantity shouldbe 25 gms.

Use bearing puller for axle shaft Pt. no. 2698 58903521, as shown

Install flange plate to the flange of axle shaft.Remove bolts from flange plate.

Assemble retainer plate, if required new; andassemble new oil seal.

Note : Rubber portion of oil seal, which extendsbeyond the casing has numbers bonded inrubber. These numbers are to face towardsthe flange of axle shaft.

Install bolt retainer.

Slide installing ring on axle shaft. Locate bearingon inside of installing ring. Slide forcing plate onaxle shaft and locate on installing ring. Install bolts.

Tighten bolts evenly until unit wheel bearing isseated. Fig. 35

Note : Bearing requires 700 kgs. to 2000 kgs.force for pressing.

Ensure proper seating of bearing by checking witha 0.038 mm. feeler gauge. Gauge should not enter.

Press retainer ring on axle shaft using suitablepress.

Insert a feeler gauge of 0.038 mm thicknessbetween retainer ring and bearing inner race. Iffeeler gauge enters, retainer ring must be forcedfarther onto axle shaft.

Note : Retainer ring requires 3200 kgs. force forproper seating.

Install snap ring.

21

REAR AXLE

Fig. 37

Fig. 38

Fig. 39Fig. 36

Assemble bearing cup into bearing bore of the tubeusing a suitable drift. Fig. 36

Make sure the cup sits properly against bearingseat of the tube.

Note : Ensure that oil seal is not damaged.

Assemble axle into housing. Fig. 37

Line up holes of retainer plate with bolts. Push axleshaft into housing as far as possible.

Tighten nuts evenly. Fig. 38

Caution : Ensure that seal and cup rib ring aredrawn evenly against the cup inhousing.

Use a torque wrench to torque nuts to specifiedvalue. Fig. 39

22

REAR AXLE

Fig. 41

Fig. 40

RING AND PINION GEAR ASSEMBLYRing gear and pinion is supplied as a sets only.They are matched with each other duringmanufacture. Matching numbers on both pinion andring gear are etched for verification. Fig. 40 or 41

If a new gear set is used, verify numbers on pinionand ring for matching before proceeding withassembly.

Standard mounting distance from center line of ringgear to back face of pinion is 109.5 mm. Thisdimension is controlled by selecting shims, whichare positioned between the inner pinion bearingcone and pinion gear. Best running position of gearset is achieved by proper shim selection.

This dimension for front live axle will be different.

On the bottom face of pinion a numbered isetched. It can be a plus (+) number, a minus (-)number or Zero (0). Required pinion shim selectionis achieved with help of this number.

If alphabet "m" appears on pinion face shimselection has to be done in mm (Metric).

If alphabet "m" does not appear on pinion faceshim selection has to be done in inches (English).

m

Shims with different thicknesses are available forselection.

Use tables on next page as a guide for selectingcorrect thickness of shims either for addition or forsubtraction from old shim pack.

Fig. 40 shows ring and pinion etched with inchidentification. Refer Table A.

Fig. 41 shows ring and pinion etched with metricindentification. Refer Table B.

Please refer tables given below for calculations :Example 1

In metric In inches

No punched on removed + 8m + 3pinion

No punch on new pinion - 5m - 2

Value derived from table + 0.13 + 0.005


Thickness of shims to be x + 0.13 y + 0.005selected for new ring/pinion

Example 2

In metric In inches

No punched on removed - 5m - 3pinion

No punch on new pinion + 5m + 4

Value derived from table - 0.1 - 0.007


Thickness of shims to be x - 0.1 y - 0.007selected for new ring/pinion

23

REAR AXLE

TABLE A

Old Pinion New Pinion Marking (English) (Value in Inches)

Marking (English) -4 -3 -2 -1 0 +1 +2 +3 +4

+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0

+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003

0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004

-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005

-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006

-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007

-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

TABLE B

Old Pinion New Pinion Marking (Metric) (Value in mm)

Marking

(Metric) -10 -8 -5 -3 0 +3 +5 +8 +10

+10 +.20 +.18 +.15 +.13 +.10 +.07 +.05 +.02 0

+8 +.18 +.16 +.13 +.11 +.08 +.05 +.03 0 -.02

+5 +.15 +.13 +.10 +.08 +.05 +.02 0 -.03 -.05

+3 +.13 +.11 +.08 +.06 +.03 0 –.02 -.05 -.07

0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10

-3 +.07 +.05 +.02 0 -.03 –.06 -.08 -.11 -.13

-5 +.05 +.03 0 –.02 -.05 –.08 –.10 -.13 -.15

-8 +.02 0 -.03 -.05 -.08 -.11 -.13 –.16 –.18

-10 0 -.02 –.05 -.07 –.10 -.13 -.15 –.18 –.20

Note: Please observe the marking on pinion. If ‘m’ is found etched on the face, refer table B. If not refer tableA.

24

REAR AXLE

PINION POSITION SHIM SELECTION

Pinion position shim selection can also be doneusing a special tool, in the absence of removedring/pinion gear.

Install pinion height set master block which is partof tool Pt. no. 2698 5890 3520 over pinion innerbearing cup seat.

Set the dial gauge to 0 (zero), on surface plate.

Install dial gauge on pinion height gauge whichagain is part of tool Pt no. 2698 5890 3520.

Install pinion height set gauge with dial gauge onside bearing seats. Ensure that plunger of dialgauge touches top face of pinion height set master.

Rock depth gauge.

Record maximum reading on gauge needle. Let itbe 'X' Fig. 42

To calculate shim thickness proceed as follows :

Shim thickness required = x - etched value onpinion (when etched+ve)

= x + etched value onpinion (when etched-ve)

Assembly pinion bearing cup

Drive inner bearing cup into carrier using toolsgiven below :

1. Installer rear pinion bearing cup Pt. No. 26985890 35 09

2. Handle Pt. No. 2698 5890 35 06. Fig. 43

Assemble outer pinion bearing cup into carrierusing tools given below :

1. Installer, front pinion bearing cup Pt. No. 26985890 35 08

2. Handle Pt. No. 2698 5890 35 06. Fig. 44

Fig. 43

Fig. 42

Fig. 44

25

REAR AXLE

Place shims selected as per procedure on piniongear and install rear pinion bearing cone; usingInstaller, rear pinion bearing cone Pt. no. 2698 58903519 Fig. 45Assemble bearing cone, slinger and new pinionseal into housing. Use Installer, pinion oil seal Pt.no. 2698 5890 3513 and handle universal Pt. no.2698 5390 3506. Fig. 46Apply a light coat of oil to the lip of oil seal.Install new collapsible spacer onto pinion stem andassemble in housing using tools given below :1. Holder, yoke Pt. no. 2698 5890 35052. Installer, yoke Pt. no. 2698 5890 3518.Assemble end yoke, washer and new pinion nut.Tigten pinion nut using torque wrench by holdingend yoke with help of special tool Pt. no. 26985890 3505. Tighten nut to specified torque or untilall end play is removed. Continue to tighten in smallincrements until specified rotating torque isachieved. Fig. 47Note: Exercise care during bearing preload torque

adjustment. Do not over tighten loosen andthen retighten nut. Do not exceed specifiedbearing preload torque.

If preload torque is exceeded, a new collapsiblespacer must be installed and torquing sequence asabove to be repeated.Check for rotating torque of pinion. It should readbetween 2.26 to 4.52 Nm with new bearings. Fig.48Note: If only oil seal needs to be changed,

measure rotating torque of pinion with thehelp special tool. In this case use newcollapsible spacer and keep same rotationaltorque of pinion as before.

Fig. 46

Fig. 47

Fig. 48Fig. 45

26

REAR AXLE

Assembly of carrier centre section

Prior to assembly, prelubricate each disc and platewith friction modifier by pre soaking for a inimum of20 minutes. Fig. 49

Assemble retainer clips to the ears of plates.

Assemble clutch pack and side gear into the case.Fig. 50

Note: Ensure clutch pack stays assembled to sidegear splines and that retainer cups arecompletely seated into the pockets of case.

Reposition case. Assemble adapter of Track Lock toolpt. no. 2699 5890 3501 plate into side gear.

Apply a small amount of grease into the centeringhole of adapter plate. Fig. 51

Assemble clutch pack and side gear on opposite side.Fig. 52

Fig. 51

Fig. 50

Fig. 52Fig. 49

27

REAR AXLE

Fig. 53

Fig. 54

Fig. 55

Hold clutch pack in position and insert threadedadapter ofTrack lock tool into side gear on top.

Insert forcing screw of Track lock tool and tighten tohold both clutch packs in position. Fig. 53

Install case into the axle shaft by aligning splines ofside gear with those of shafts.

Loosen forcing screw slightly and assemble bothpinion mate gears. Fig. 54

Hold gears in position by hand and insert turning barinto case.

Pull on bar to rotate case allowing gears to turn.

Note: Ensure that holes of pinion mate gears are inalignment with holes of case.

Prelubricate spherical washers. Tighten screw of Tracklock tool to collapse Belleville plates. Assemblespherical washers into case. Fig. 55

Caution: Ensure holes of washers and gears are linedup exactly with those of case.

28

REAR AXLE

Fig. 57

Fig. 56

Fig. 58

Remove all tools.

Assemble cross pin shaft. If required use a suitabledrift to guide cross pin. Fig. 56

Use a small drift to fit roll pin on cross shaft. Fig. 57

As the role pin bottoms out, stake (peen) a little metalover edges in two places 180O apart. Fig. 58

29

REAR AXLE

Fig. 60

Fig. 61

Fig. 62Fig. 59

Assembly of Differential

Assemble Master differential bearings Pt. No. 26985890 35 14. Fig. 59

Assemble differential case into carrier. (Less ringgear.) Mount dial indicator with a magnetic base.

Locate its tip on that surface of case & forcedifferential assembly to the extreme in the directiontowards the indicator. Fig. 60

With force still applied, set indicator to 0.00.

Force differential assembly to the extreme end inopposite direction. Fig. 61

Repeat above steps until the same reading isobtained. Fig. 60

Record reading in the format given as ‘A’.

Remove master bearing and set aside.

Assemble ring gear to case.

Note: Use new ring gear screws. Torque ring gearscrews to specification. Fig. 62

30

REAR AXLE

Fig. 64

Fig. 63

Assemble master differential bearing Pt. No. 26985890 3514 on to case hubs.

Place differential assembly into housing. Install dialgauge and locate tip of indicator on the surface ofone of the ring gear screws.

Force differential case assembly away from piniongear. With force still applied set indicator at 0(Zero). Fig. 63

Force differential case assembly and ring gear tomesh with pinion gear. Fig. 64

Rock ring gear to allow teeth of the gear to meshRepeat to obtain a stable reading. Record in givenformat as B. Fig. 63

Remove indicator and master differential bearings.

WORK SHEET FOR CALCULATION OF RINGGEAR BACKLASH AND SIDEBEARING PRELOAD SHIMS

1. Total amount of space Measurement Ameasured without ring gear.

2. Total amount of space Measurement Bmeasured with gear set assembled in carrier.

3. Measurement A minus Measurement CMeasurement B.

Assemble shim pack using figures determined in A, B & C. Adjust packs as described below.

RING GEAR SIDE :

Assemble shim pack to measurement B - 0.125 mm. or B – 0.005"

OPPOSITE SIDE OF RING GEAR :

Assemble shim pack to measurement C. Add 0.20 mm or C+0.008" for side bearing preload and backlash.

Ring Gear Side

Opposite Side ofRing Gear

31

REAR AXLE

Fig. 66

Fig. 67

Fig. 68Fig. 65

Assemble selected shims pack on hub ofdifferential case. Place side bearing cone aboveshims. Install bearing cone in its seat using toolsgiven below :

1. Installer differential side bearing Pt. no. 26985890 3512

2. Handle Pt. No. 2698 5890 3506. Fig. 65

Repeat this procedure for installation of shims/bearing cone on opposite side of differential case

Install spreader and dial indicator. Spread thecarrier. Do not spread it over 0.58 mm. Fig. 66

Remove dial indicator.

Install differential case assembly into carrier.Fig. 67

Caution : Carelessness while installing differentialcase asssembly may result in injury.

Install bearing caps. Fig. 68

Ensure correct fitment of caps by matching letterson caps and carrier on either side.

Torque bearing cap screws to specification.

32

REAR AXLE

Fig. 70

Fig. 69

Check ring gear and pinion backlash at threeequally spaced points with dial indicator. Fig. 69

Backlash tolerance is 0.13 to 0.20 mm. and shouldnot vary more than 0.08 mm. between the threepoints checked.

High backlash is corrected by moving ring gearcloser to pinion. Low backlash is corrected bymoving ring gear away from pinion.

These corrections are made by switching shimsfrom one side of differential case to other.

If backlash is to specification check ring gear andpinion tooth contact pattern.

INTERPRETING RING GEAR AND PINIONTOOTH PATTERN

Toe of gear tooth is the portion of the tooth surfaceat the end toward center. Heel of gear tooth is theportion of tooth surface at outer end. Top land of agear is the surface of top of the tooth. Fig. 70

Illustrations explain how contact pattern shift asgear location changes.

When making pinion position changes, shimsshould be changed in steps of 0.05 mm, untilcorrect pattern has been obtained.

When a change in backlash is required, shimsshould be changed in the range of 1.5 times theamount of backlash required. For example, ifbacklash must be changed by .10mm shim packshould be changed by .15mm as a starting point.Actual amount of backlash change obtained willvary, depending upon the ratio and gear size.

Note: Making changes involves two variables.Example : if you have the backlash setcorrectly to specifications and you changethe pinion position shim, you may have toreadjust the backlash to the correctspecification before checking the pattern.Refer to pattern interpretation.

33

REAR AXLE

Paint right gear teeth with a marking compound onboth drive and coast side.

Rotate ring one complete revolution in bothdirections while applying load with a largescrewdriver between carrier casting and differentialcase flange.

Refer Fig. 71

A. Normal or desirable pattern. Drive patternshould be centered on the tooth. Coastpattern should also be centered on the tooth,but may be slightly towards the toe. Thereshould be some clearance between thepattern and top of the tooth.

B. Backlash correct. Thinner pinion positionshim required.

C. Backlash correct. Thicker pinion positionshim required.

D. Pinion position shim correct. Decreasebacklash.

E. Pinion position shim correct. Increasebacklash.

Pattern movements summary

● Decreasing backlash moves the ring gearcloser to pinion.

Drive pattern (convex side of gear) movesslightly lower and toward the toe.

Coast pattern (concave side of gear) moveslower and toward the toe.

● Increasing backlash moves ring gear awayfrom pinion.

Drive pattern moves slightly higher andtoward the heel.

Coast pattern moves higher and toward theheel.

● Thicker pinion position shim with backlashconstant moves pinion closer to ring gear.

Drive pattern moves deeper on the tooth andslightly toward the toe.

Fig. 71

Coast pattern moves deeper on the toothand slightly toward the heel.

● Thinner pinion position shim with thebacklash constant moves pinion farther fromring gear.

Drive pattern moves toward top of the tooth(face contact) and toward heel.

Coast pattern moves toward top of the toothand slightly toward toe.

34

REAR AXLE

INSTALLING COVER PLATE ON CARRIER

Cover face of the carrier and flat surface of thecover plate must be free of any oil film or foreignmaterial.

Apply sealer to cover place surface. Ensure thatsealer bead is on the inside of cover screw holes.Fig. 72

Bead must be 3 to 6 mm high and 3 to 6 mmwide.

Install cover screws into cover at 8-'O’clock and 2-'O’clock positions. Use two holes to guide coverplate into position on the carrier.

Install remaining screws. Fig. 73

Tighten alternately and evenly. Torque screws to 38-45 Nm.

Allow one hour cure time before vehicle operation.

Measuring Axle end play

With a magnetic stand and dial, locating it on aproper base, make the dial pointer to touch theflange face of axle shaft.

Pull the flange towards you and set dial to zero atthis point.

Now Push the flange away from you and mark thedial reading at this point.

This is axle end play reading. This should bewithin specified values.

Assemble brake drum and put wheels. Tightenwheel nuts to specified torque.

Note : To measure axle end play with axleassembly installed on the vehicle proceedas given below.

Support the vehicle by placing two V-stands under the axle locating it on tubes.Confirm axle is in horizontal plane andvehicle is steady.

Take out wheel and brake drum. Measureend play as above.

Fill specified quantity of oil. Use drive square fordrain plug. Pt. no. 2654 5890 3524. to tighten thedrain plug to specified torque.

CONTOUR OF BEAD

Fig. 72

Fig. 73

Installation of axle assembly :

Install the axle in reverse order of steps of removalof axle from vehicle.

35

REAR AXLE

TROUBLE SHOOTING - AXLE ASSEMBLY

CONDITION POSSIBLE CAUSES

Noise in all driving modes Road and tires, wheel bearings

Noise changes with type of road surface Road and tires

Noise tone lowers with car speed Tires

Noise louder on turns Differential pinion and side gears, axle wheel bearings

Noise in one or more driving modes Ring and pinion gears

Metallic noise on change of speed or Worn differential shaft or thrust washers; worn U-jointsdirection of power flow

Wheel noise Wheel loose; faulty or bad wheel bearing

Vibration Damaged drive shaft, missing drive shaft balance weight,worn or out-of-balance wheels, loose wheel nuts, wornU-joints, loose spring U-bolts, loose/broken spring,damaged axle shaft bearings, loose pinion gear nu’,,excessive pinion yoke run out, bent axle shaft.

Differential gears scored Insufficient lubrication, improper grade of lubricant,lubricant contamination, excessive spinning of wheels.

Loss of lubricant Lubricant level too high, worn axle shaft seals, crackeddifferential housing, worn drive pinion gear shaft seal,scored and worn yoke, axle cover not properly sealed,plugged vent or vent tube.

Axle overheating Lubricant level too low, incorrect grade of lubricant,contaminated lubricant, bearing preload too high,excessive gear wear, insufficient ring gear backlash.

Gear teeth broken Overloading, erratic clutch operating, wheel spinning,improper adjustment

Axle gear noise Insufficient lubricant, incorrect backlash, improper toothcorrtact worn/damaged gears

Axle noise Insufficient lubricant, improper ring gear and drive piniongear adjustment, unmatched ring gear and drive piniongear, worn teeth on ring gear or drive pinion gear, Loosedrive pinion gear shaft bearings, loose differentialbearings, misaligned ring and pinion gear, loosedifferential bearing cap screws, worn bearings.

'Chatter' noise from Limited slip differential Probable cause is incorrect or contaminated lubricantwhile cornering or lack of friction modifier additive in lubricant.

Worn or damaged bellivelle plates and discs.

Otherwise bellivelle plates and discs improperly assembled.

1

WHEELS & TYRES

WHEELS & TYRES

3

WHEELS & TYRES

Pneumatic tyres are fitted to provide good ride &handling of the vehicle. A good wheel and tyreassembly ensures that no harsh & bumpy ride isexperienced and least rolling resistance is encounteredfor improving fuel economy.

INTRODUCTION :

4

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WHEELS

1 Tubeless tyre LT 205/80 R16

2 Valve Tr No. 415

3 Assy. Wheel Rim 5.5J x 16

4 Wheel Nut

5 Assy. Wheel Rim cover

Wheel rim & Tyre

Fig. 1

5

WHEELS & TYRES

Fig. 2

WHEELS AND TYRES

TYRES :

Vehicle is equipped with 205/80 R16 radial tubelesstyre. Tyre is designed to operate satisfactorily withloads upto full rated load capacity when inflated torecommended inflation pressures. It is important tomaintain correct tyre pressures. Heavy cornering,excessively rapid acceleration, and unnecessarysharp braking increases tyre wear.

WHEELS :

Wheel rim size : 5.5 J x 16 Steel.

Advantange of tubeless tyres :1] Air leakage after puncture is very slow.

2] Better fuel efficiency.

3] Less chance of run-flat damages.

4] No tube related problems.

5] Less balance weight required.

6] Easy repairing.

Special care for tubeless tyre :

1) Do not stand over tyre when inflating. Bead maybreak when bead snaps over rim's safety humpand cause serious personal injury.

2) Do not exceed specified pressure when inflating.If specified pressure will not seat beads, deflate,re-lubricate and reinflate.

3) While removing tyre from wheel rim andmounting it back on wheel rim, takeprecautions not to damage tyre bead. Use tyreremoval and assembly machines. Damage orcut on tyre bead may cause gradual loss ofair and deflation of tyre.

4) Do not scratch inside of tubeless tyre withmetallic or sharp object. Tubeless tyres arecoated with impermeable layer of rubber frominside which hold the air inside tyre. Removalof this layer due to scratching may causegradual loss of air and deflation.

5) If wheel rims get damaged in service, get thewheel rims repaired/replaced immdiately.Running the vehicle with damaged rim mycause deflation of tyre and subsequentdisloging of tyre from rim.

Lateral

Radial

6) Maintain recommended inflation pressures intyre. Over in flation, in particular, may causepuncture or bursting of tyre.

6

WHEELS & TYRES

Fig. 3

valve

Replacement Tyres :

When replacement is necessary, tyre recommendedonly should be used. Replacement tyres should be ofthe same size, load rating and construction as thoseoriginally on the vehicle. Use of any other size ortype tyre may affect ride, handling, speedometer/odometer calibration, vehicle ground clearance andtyre clearance to the chassis.

It is recommended that new tyres be installed in pairson same axle. If necessary to replace only one tyre,it should be paired with the tyre having the most tread,to equalize braking traction.

Also, do not mix different types of tyres (viz. radial,bias etc) on the same vehicle, because it badly affectsthe handling of the vehicle. Tyre pressures is usuallyprinted on sticker, stuck on driver side door.

Replacement of wheels :

Wheels must be replaced if they are bent, dented,have excessive lateral or radial runout, air leak throughwelds, have elongated bolt holes, if lug nuts won'tstay tight, or if they are heavily rusted. Wheels withgreater runout than specification may cause vibrations.

Replacement wheels must be equivalent to the OEwheels in load capacity, diameter, rim offset andmounting configuration.

A wheel of improper size or type may affect wheeland bearing life, brake cooling, speedometer/odometercalibration, vehicle ground clearance and tyreclearance to body and chassis.

How to measure wheel runout :

Wheel runout has to be measured by installing it in awheel balancer & using a dial indicator. Wheel runoutcan be checked in tyre installed condition.

Take measurements of lateral & radial runouts atinside/ outside of rim flange. Turn wheel one fullrevolution slowly and record maximum reading of theindicator. (Fig.2)

Both lateral & radial runout should not exceed 1.5 mm.

When runout exceeds the specification and correctionby balancer adjustment is not possible, replace wheel.

Matched tyres and wheels :

Tyres are match mounted by us at Works. Radiallyleast stiff part of the tyre or "low spot" marked yellowon side wall of tyre is matched to the valve location ofassembly.

This is done to provide smoothest possible ride byreducing assembly imbalance.

Whenever a tyre is dismounted from wheel, it shouldbe remounted so that the tyre paint dot & valvelocation are matched. If the tyre's paint dot can not belocated, a line should be marked on the tyre and wheelbefore dismounting to assure that it is remounted inthe same position.

7

WHEELS & TYRES

Inflation of Tyres :

Recommended tyre pressure is carefully calculatedto give a satisfactory ride, stability, steering tread wear,tyre life and resistance to bruises.

Tyre pressure, with tyres cold, (after vehicle set forthree hours or more, or driven less than one mile)should be checked monthly or before any extendedtrip.

It is normal for tyre pressure to increase (4 psi approx.)when the tyres become hot during driving. Do notbleed or reduce tyre pressure after driving. Bleedingreduces the “Cold Inflation Pressure”.

Valve caps should be on the valves to keep dust andwater out.

Higher than recommended pressure can cause :

1. Hard ride

2. Tyre brushing or carcass damage

3. Rapid tread wear at center of tyre

Unequal pressure on same axle can cause :

1. Uneven braking

2. Steering pull

3. Bad handling

Lower than recommended pressure can cause :

1. Tyre squeal on turns.

2. Hard steering

3. Rapid and uneven wear on the edges of the tread

4. Tyre rim bruises and rupture

5. Tyre chord breakage

6. High tyre temperature

7. Bad handling

8. High fuel consumption

8

WHEELS & TYRES

Tyre Rotation :

To equalize wear, rotate tyres according to figure No.4periodically. Set tyre pressure.

NOTE :

Due to their design, radial tyres tend to wear faster inthe shoulder area, particularly in front positions. Thismakes regular rotation necessary.

Wheel Removal :

1. Loosen all wheel nuts (M14 x 1.5) byapproximately 180 deg. (half a rotation).

2. Hoist vehicle

3. Remove nuts and then wheel

Wheel nuts must be tightened in sequence given infigure and to proper torque to avoid bending wheel orbrake disc. (Figure 5)

NOTE :

Clean all parts and remove any build up of corrosionany parts, before installation of the wheel.

Never heat any part to loosen tight wheel, it willshorten life of wheel and bearings.

Tightening Torque :180 Nm - 195 Nm (18-19.5 kgm)

Tyre Mounting and Demounting :

Use a tyre changing machine to mount or demounttyres. Follow equipment manufacturer's instructions.Do not use hand tools or tyre irons alone to changetyres as they may damage tyre beads or wheel rim.

Rim bead seats should be cleaned with a wire brushor coarse steel wool to remove lubricants, old rubberand light rust.

After mounting, inflate to specified pressure so thatbeads are completely seated.

Fig. 4

Fig. 5

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SPARE WHEEL CARRIER

1 ASSY. TUBE

2 RUBBER BUSH

3 CLAMP

4 HEX SCREW M8 X 20

5 SPRING WASHER B8

6 HEX NUT M8

7 SCREW WITH NYLON INSERT

8 BRIGHT WASHER 10.5

9 ASSY. SUPPORT (SPARE WHEEL MTG),

10 PLASTIC BUSH

11 SPH. WASHER 13

12 SPRING WASHER 13

13 HEX. BOLT

14 PIN

15 DISC SPRING B25

16 SPACER

17 NYLOC NUT M10

18 ASSY CLAMP

19 HEX. SCREW

DESCRIPTIONSR.NO

Fig. 6

10

WHEELS & TYRES

Removal of Spare Wheel

1) For removing spare wheel, unscrew the Hexscrew which is holding the clamp (18) andspare wheel support bracket (9).

2) Holding the spare wheel support bracket &spare wheel with one hand, rotate the clampby approx. 450 with other hand in clockwisedirection (when viewed from rear of vehicle).

3) Holding the clamp in rotated position, gradu-ally lower the spare wheel support bracketalong with spare wheel. Lower till spare wheeltouches the ground.

4) Unscrew the Hex bolt and fasteners (10 to13) which clamp the wheel rim on sparewheel support bracket.

5) Lift the spare wheel and take it out fromspare wheel support bracket.

Assembly of spare wheel

Assembly of spare wheel is in reverse order ofremoval.

Fig. 7

11

WHEELS & TYRES

Balancing Wheels :

Dynamic balance, as shown in Fig. 8, is the equaldistribution of weight of each side of the wheel centerline so that when the tyre spins there is no tendencyfor the assembly to move from side to side. Wheelsthat are dynamically unbalanced may cause shimmy.

1. Permissible imbalance for tyre with rim = 250 gm-cm max.

2. Total balance weight should be within 140 gmson each side.

3. Relocate the tyre if the weight required to balanceis more than 140 gm.

4. Balance weights are available from 10 gms to140 gms in steps of every 10 gms and from 15gms to 135 gms in steps of every 10 gms.

5. Do not use more than one balance weight on oneside.

General Balance Procedures :

Deposits of mud, etc. must be cleaned from inside ofrim.

Warning :

Remove stones from tread, clean the tyre and rimbefore balancing for safety & to achieve better results.

Each tyre should be inspected for any damage, thenbalanced according to equipment manufacturer'srecommendation.

Off-Vehicle Balancing :

Most electronic off-vehicle balancers are moreaccurate than the on-vehicle spin balancers. Theyare easy to use and give a dynamic (two plane)balance. Although they do not correct for drum or discunbalance as does on vehicle spin balancing, this isovercome by their accuracy.

Fig. 8

12

WHEELS & TYRES

Wear on the outeredges.

Possible cause -Under-inflated tyres.If the tyre is under-inflated the outeredges (shoulders) ofthe tyre will be themain part that is incontact with the road.

Wear on the centresection of the tyre.Possible cause -Over-inflated tyres.

If the tyre is over-inflated the tyre willbulge in the middlewith the centresection of the tyrebeing the main part incontact with the road.

Wear on one side ofthe treadPossible cause -Wheel alignment isout.

Feathered treads(easier to feel than see)

Possible cause - Wheelalignment out.

Irregular bald spots

Possible cause -Unbalanced tyre.

Cupped depressions

Possible cause - Wornshock absorbers orunbalanced brakingsystem.

Steering Wobble

If you are experiencing any form of steering wheel “wobble” or drivingdisturbances, it could be that your tyre & wheel assembly needbalanced.

Wheel Balancing

Steering “wobble” is usually caused by a tyre not being “balanced”. Most tyre& wheel assembly require a balance weight to be attached to them whentyres are fitted and these may fall off over time.

TROUBLE SHOOTING CHART - TUBELESS TYRES

1

PROPELLER SHAFT

PROPELLER SHAFT

3

PROPELLER SHAFT

The propeller shaft used is a Quick Disconnect HalfRound End Yoke type.

It has a torque carrying capacity of 2000 Nm and amaximum operating speed of 6000 rpm.

The cross and bearing in universal joint as well as theshaft support (centre) bearing are lubricated for life.

There are no lube fittings.

INTRODUCTION :

5

PROPELLER SHAFT

CONTENTS


1. Construction 07

2. List of Special Tools & Service Data 09

3. Removal from Vehicle 10

4. Disassembly 10

5. Inspection 13

6. Lubrication 15

6. Assembly 16

7. Installation on Vehicle 18

8. Trouble Shooting 19

7

PROPELLER SHAFT

CONSTRUCTION

Fig. 1 4 x 2 Front propeller shaft

CUP ASSY.

CROSS

CIRCLIP

TUBE YOKE

TUBE

MIDSHIP TUBE SHAFT

SLINGER

BRACKET

BEARING

RUBBER BEARING

SPACER

RETAINER

CLAMP

DUST SEAL

DUST SEAL RETAINER

INT. END YOKE

WASHER

NUT

SR. NO. DESCRIPTION

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

8

PROPELLER SHAFT

CONSTRUCTION

Fig. 2 4 x 2 Rear Propeller Shaft

CUP ASSY.

U-J CROSS ASSY.

CIRCLIP

SLIP YOKE

DUST CAP ASSY

TUBE SHAFT

TUBE

TUBE YOKE

SR. NO. DESCRIPTION

1.

2.

3.

4.

5.

6.

7.

8.

9

PROPELLER SHAFT



1. Holder for coupling yoke 2698 5890 35 05or 2698 5890 41 02

2. Puller for center bearing 312 589 25 33

3. Socket for end yoke nut. 2698 5890 41 01

SERVICE DATA

Tightening Torque :

End Yoke nut 14-16 mkg

Bearing strap retaining bolt 1.8 - 2.2 mkg.

Adjustment Data :

Maximum permissible displacement in lateral axial 0.15 mm.direction under load of 3.3 kgm.

Maximum permissible radial or axial looseness 0.18 mm.between the slip yoke & tube shaft

Maximum Permissible dynamic unbalance 18 gm cm at 3200 rpm.

Total Indicator Reading of Maximum 0.25 mm.permissible ovality

Runout to be measured within 12.7 mm of tube 0.76 mmlength centre and within 80 mm of tube-weldlocation at both ends

Grease splines at the intervals. 10,000 km. / 6,000 miles

Use :

W/NLGI 2 - Grade grease for slip spline

10

PROPELLER SHAFT

REMOVAL FROM VEHICLE

Note : Before removal of the driveshaft set thebrakes, block the wheels, and mark the slipyoke assembly and tube shaft with a markingstick or paint to assure prope r alignment whenreassembled. This is known as keeping thedriveshaft yokes “in Phase”.

Unscrew bearing strap retaining bolts at pinion yoke.

Unscrew bearing strap retaining bolts of the rear shaft,at centre bearing joint for 4x2 vehicle & at transfercase for 4x4 vehicle. Disconnect & remove rearpropeller shaft. Fig. 2.

Carefully place the propeller shaft on a work table.

For 4x2, Unscrew nuts to remove centre bearingbracket from cross member & unscrew bearing strapbolts at the gear box, to disconnect front propellershaft.

For 4x4, Unscrew bearing strap bolts at the front axletail pinion end yoke & transfer case end yoke andDisconnect front propeller shaft.

Unscrew end yoke mounting nut by holding the yokewith holder Pt. no. 2698 5890 3505 or Pt. no. 26985890 4102 and using socket Pt. no. 2698 5890 4101at gear box or at the transfer case.

Unscrew end yoke mounting nut at tail pinion byholding yoke with the same holder as above and usinga suitable socket. Fig. 3

Place all parts on work table.

DISASSEMBLYNote : The unitized one piece seal used on Spicer

driveshafts is not intended to be removed inservice. To separate the tube shaft from theslip yoke, pull the tube out of the slip yoke,leaving the seal in place.

A significant amount of force is required to remove aswell as reinstall the tube shaft through the seal.

Removal of the unitized seal causes damage to theseal lip where it contacts the slip yoke.

Fig. 3

To remove the old seal, hold the yoke assembly firmlyin a vise. Using a large chisel, drive the seal off theyoke.

FOR 4x2

Disassembly of Centre Bearing. Refer fig.1.

Mount holder Pt. no. 2698 5890 35 05 or 2698 5890 4102 on end yoke. Grip the holder in vice. Unscrew andremove end yoke mounting nut with socket. Pt. no.2698 5890 41 01.

Remove holder.

11

PROPELLER SHAFT

Fig. 5

Fig. 6

Fig. 7

Pull out end yoke. Fig.4

Unstake clamping strap and remove centre bearingbracket. Fig.5

Slide off rubber housing from centre bearing assembly.

Remove rear spacer ring.

With puller Pt. No. 312 589 25 33 pull out centre bear-ing assembly from propeller shaft. Fig. 6

Remove front spacer ring.

DISASSEMBLY OF UNIVERSAL JOINT :

Using a soft drift, tap the outside of the bearingassembly to loosen snap ring. Tap bearing only hardenough to break assembly away from snap ring. Fig. 7

Fig. 4

12

PROPELLER SHAFT

Fig. 8

Fig. 9

Fig. 10

Remove snap ring from yoke. Turn joint over, tapbearing away from snap ring, then remove oppositesnap ring. Fig. 8

Set the yoke in the arbor press with a piece of tubestock beneath it. Position the yoke with the tube fittingbearing up to prevent interference during disassembly.Place a solid plug on the upper bearing assembly andpress it through to release the lower bearing assembly.Fig. 9

If the bearing assembly will not pull out by hand afterpressing, tap the base of the lug near the bearingassembly to dislodge it.

To remove the opposite bearing assembly, turn theyoke over and straighten the cross in the open crosshole. Then carefully press on the end of the cross sothe remaining bearing assembly moves straight outof the bearing cross hole. Fig. 10

Repeat this procedure on the remaining bearingassemblies to remove the cross from the yoke.

13

PROPELLER SHAFT

Fig. 12

Fig. 13

Fig. 14Fig. 11

INSPECTION

Check the output and input end yokes for looseness.If loose, disconnect the drive shaft and re-torque theend yoke retaining nut to specification, using a newnut. Fig.11

Check condition of the spline of end yoke.

Check the U. J. cross for defects like Brineiling andEnd Galling. Fig. 12

Check for excessive looseness across the ends ofthe bearing assemblies and trunnions. This loosenessshould not exceed 0.15 mm maximum. Fig. 13

If necessary, replace U. J. cross.

Check the slip spline for excessive radial movement.Radial looseness between the slip yoke and the tubeshaft should not exceed 0.15 mm. Fig. 14

14

PROPELLER SHAFT

Fig. 15

Fig. 16

Fig. 17

Check the shaft for damage, bent tubing or missingbalance weights. Make certain there is no build up offoreign material on the shaft such as undercoat orconcrete. If found, remove it carefully to avoid damageto the drive shaft. If shaft is found bent, straighten it.Fig.15

Check for runout. Check tube for ovality.

Remove the end yoke from the drive shaft and placein a soft jawed vise to inspect the cross hole surfaces.Raised metal can be removed with a rat tail or halfround file. Emery cloth should be used to remove allrust and corrosion from cross hole bores. Fig. 16

Runout readings are taken with the drive shaft mountedin the vehicle with the transmission in neutral and theaxle shafts pulled or by jacking rear wheels off theground and placing axles on jack stands. This will allowrotating the drive shaft by hand to check indicatorreadings. The runout readings taken at the variouslocations should not exceed an additional 0.25 mm.Total Indicator Reading over the specified runout.Fig. 17

INSPECTION OF CENTRE BEARING

Clean all parts thoroughly.

Note : Do not apply solvent in bearing assembly andrubber housing.

Check the following :

Condition of splines and threads on shaft.

Condition of splines and holes on coupling flange.

Condition of rubber housing. Replace with new one ifnecessary.

Condition of centre bearing bracket bearing surfaceand mounting holes.

Figure is only for illustration

15

PROPELLER SHAFT

Fig. 18

Fig. 19

Fig. 20

Condition of clamping strap for any damage speciallyat crimping portion.

Free and smooth rotation of bearing unit in centrebearing assembly.

The bearing should have negligible radial play.

Condition of dust seals in centre bearing assembly.

If any of the above defects are noticed in the centrebearing assembly, complete centre bearing assemblyshould be replaced.

Condition of dust caps on propeller shaft and couplingflange. These are tack welded to respectivecomponents.

Check both spacer rings for wear score marks. If founddefective replace with NEW one.

Replace defective parts.

LUBRICATION

PRELUBE OR LUBE FOR LIFE DESIGNS

Universal joint crosses and bearings are prelube orlube for life designs and have no lube fittings. Specialseals are used to contain the lubricant in the crossbearings in this design. Fig.18

Replacement of the cross and bearing kit isrecommended rather than relubrication.

LUBRICATION FOR SLIP SPLINES

Apply grease gun pressure to the tube fitting untillubricant appears at the pressure relief hole in the plugat the slip yoke end of the spline. Fig.19

Now cover the pressure relief hole with your fingerand continue to apply pressure until grease appearsat the slip yoke seal. Fig.20

Caution : In cold temperatures be sure to drive thevehicle immediately after lubricating. Thisactivates the slip spline and removes theexcessive lubricant. Failure to do so couldcause the excess lubricant to stiffen in thecold weather and force the plug out. Theend of the spline would then be open tocollect contaminants and cause the splineto wear and/or seize.

LUBE FOR LIFE CENTRE BEARING :

Centre bearing is packed with grease for life. No fillingof bearing with grease is recommended.

Cover relief hole

16

PROPELLER SHAFT

ASSEMBLY

FOR 4X2

ASSEMBLY OF CENTRE BEARING ON FRONTPROPELLER SHAFT

Pack cavities between dust seals and centre bearingwith lithium base grease (bearing grease)

Smear grease on the seating surface of centre bearingon front propeller shaft.

Install centre bearing assembly on front propeller shaftrear end. Fig.21

Install other spacer ring of centre bearing on propellershaft bearing, using a suitable drift.

Apply glycerin on inner periphery of rubber housingand slide it on to the centre bearing assembly.

Apply grease on the splines of front propeller shaftand coupling flange. Insert end yoke on front propellershaft. Fig.22

Screw in NEW end yoke mounting nut on front propellershaft.

Mount holder Pt. no. 2698 5890 3505 or Pt. no. 26985890 4102 on end yoke. Clamp holder in vice andtighten coupling flange nut.

Assemble centre bearing bracket and clamping strapon rubber housing. Clamp strap on to the bracket atboth ends. Ensure that there are no cracks at crimping.

ASSEMBLY OF UNIVERSAL JOINT

Position the cross in the yoke. Fig.23

Fig. 21

Fig. 22

Fig. 23

17

PROPELLER SHAFT

Move one end of the cross to cause a trunnion toproject through the cross hole beyond the outermachined face of the yoke lug. Place a bearingassembly over the trunnion diameter and align it tothe cross hole. Using an arbor press, hold the trunnionin alignment with the cross hole and place a solidplug on the upper bearing assembly.

Press the bearing assembly into the cross hole enoughto install a snap ring. Fig.24

Install a snap ring. Fig.25

Repeat the above two steps to install the oppositebearing assembly. Fig.26

If the joint is stiff, strike the yoke ears with a softhammer to seat the needle bearings. Fig.27

Caution : Be sure that snap rings are properlyseated in grooves.

Repeat the above steps at the opposite end of thedrive shaft in installing a second kit.

If removed earlier, the unitized seal should be replacedwith a new unit.

Install a new seal by generously lubricating the seallip and press it over slip yoke using a small arborpress.

Fig. 25

Fig. 26

Fig. 27Fig. 24

18

PROPELLER SHAFT

Assemble tube shaft and slip yoke, making sure thatthe alignment marks are in line. This will ensure thatslip yoke lugs and tube yoke lugs are in line. Fig.28

INSTALLATION :

PREPARING FOR INSTALLATION

In propeller shaft assembly, when there is replacementof worn cross and bearing assemblies with a new kit,it is desirable to rebalance it.

Take runout with entire drive shaft assembly mountedon master tooling which locates on the outboardbearing assemblies of the u-joint kit.

All yokes should be selected for dynamic balance toeliminate as much unbalance as possible. Duringbalancing, the drive shaft again should be mountedon the same master tooling or yokes.

After straightening, balance the entire assembly tothe specified limit.

INSTALLATION ON VEHICLE

Before installation ensure that :

Splines should slide freely with slight drag from splineshaft seal.

Cross should flex and be free from excessive bind.

Note : A slight drag is the most desirable conditionon a new cross and bearing kit. Excessivelooseness is not desirable and will result in anunbalanced drive shaft.

Mounting Flange should be free from burrs, paint andforeign substances which would not allow properseating at assembly.

While installing and servicing system balancedassemblies, The following rules should be strictlyadhered to :

End yokes must not be rotated from their originalposition during reassembly.

FOR INSTALLATION PROCEED INTHE REVERSEORDER OF REMOVAL.

Tighten the mounting nuts 8 bearing strap bolts tospecified torques.

Caution : Self locking bolts used with bearingstrapsshould not be reused.

Fig. 28

19

PROPELLER SHAFT

TROUBLESHOOTING

COMPLAINTS CAUSES CORRECTION

VIBRATION Improper phasing Replace u-joint

Loose outside diameter fit on slip Straighten and balance shaftspline Replace shaft bearing

Driveshaft out of balance, Check driveshaft for correct yoke

Worn u-joint phasing.

Inadequate torque on bearing strapbolts.

PREMATURE WEAR Improper lubrication Replace the affected parts.

Excessive u-bolt torque onretaining nuts

Worn or damaged seals

SLIP SPLINE WEAR Improper lubrication Lubricate slip spline according toWorn or damaged part specifications

Contamination Check for installed lengths checkcondition of slip yoke seal.

YOKE FRACTURE Mating yoke lug interference at full Replace yokejounce and rebound

TUBE BENT Balance weight located in apex of Normal bearing wear - replaceweld yoke lug area

Balance weight too close to circle Check installed lengthsweld

Improper circle weld Realign mounting bracket to frameShaft support bearing misaligned cross member to eliminate– interferes with slinger interference with slinger.

1

BRAKES

BRAKES

3

BRAKES

INTRODUCTION :

Vaccum assisted hydraulic brake system hasbeen provided.

System consists of disc brakes in front & drumbrakes in rear.

A dual hydraulic brake circuit consisting oftandem master cylinder & calipers in front / wheelcylinders in rear has been provided to actuatefront & rear brakes.

Hydraulic pressure developed by tadem mastercylinder is transmitted to caliper assembly (frontcircuit) and wheel cylinder (rear circuit) to actuatebrake pads/shoes.

Vaccum assistance is provided by vaccum pumpon mounted on alternator.

In the event of failure in one circuit, other oneremains unaffected and vehicle can be broughtto a halt.

5

BRAKES

CONTENTS


1. Schematic circuit of brake lines (LHD) 6

Schematic circuit of brake lines (LHD) 7

2. Specifications 8

3. Tightening Torques 9

4. Front disc brakes :

a. Salient features of disc brakes 10

b. Brake maintenance 11

5. Rear brakes :

a. Rear drum brakes 17

b. Brakes Maintenance 18

c. Major overhaul 18

d. Wheel cylinders 20

6. Tandem master cylinder 22

7. Bleeding the brake system 29

8. Vacuum booster

a) Conventional (Yellow Housing) 31

b) Zero Dead Stroke (Black Housing) 35

c) Check list for proper functioning 47

d) Preventive maintenance 48

9. Console mounted parking brake 51

10. Brake pedal height adjustment 53

11. Load conscious pressure reducing valve 54


6 BR

AK

ES

FRONT BRAKE CALIPER LH

Fig. 1 - Schematic Circuit of Brake Lines (LHD)

FRONT BRAKE

HOSE

FRONT BRAKE CALIPER RH

FRONT BRAKEHOSE

FRONT BRAKE

PIPE

BRAKE FLUIDBOTTLE WITHAUTOMATIC LEVELINDICATOR

SERVO UNIT AND

MASTER CYLINDER

VACUUM PIPE

VACUUM

HOSE

VACUUM PUMP

REAR WHEELCYLINDER

RH

REAR WHEELCYLINDER

LH

REAR BRAKEHOSE

REAR BRAKE PIPELCRV

7

BR

AK

ES

FRONT BRAKE CALIPER LH

Fig. 1a - Schematic Circuit of Brake Lines (RHD)

FRONT BRAKE

HOSE

FRONT BRAKE CALIPER RH

FRONT BRAKEHOSE

FRONT BRAKE

PIPE

BRAKE FLUIDBOTTLE WITHAUTOMATIC LEVELINDICATOR

SERVO UNIT AND

MASTER CYLINDER

VACUUM PIPE VACUUM

HOSE

VACUUM PUMP

REAR WHEELCYLINDER

RH

REAR WHEELCYLINDER

LH

REAR BRAKEHOSE

REAR BRAKE PIPELCRV

8

BRAKES

SPECIFICATIONS

BRAKES

Front

Type : C 57 ColetteSingle Pot (Sliding Caliper)

Size : Piston dia. 57 mmBrake disc thickness 21.0 mmDiscard thickness : 19.0 mmPad thickness : 11.3 ±0.5 mmDiscard thickness : 7.0 mm

Rear

Type : Hydro non-servo sliding shoe brakeLeading Trailing Shoe Drum Brakewith Hand Brake attachment

Size : Drum dia : 282mmDrum dia : 283.6 ±0.1 mm (RS)Brake Lining width 50.8 mmBrake lining thicknessSTD : 6.0 ±0.45mmRS : 6.8 ±0.45mmLining used : TVS AF 2873 GG

Rear Wheel Cylinder - Double Acting

Dia. (mm) - 22.2

Brake Front Rearlining area 99.6 cm2/wheel 287.46 cm2/wheel

Type of Moulded Rivettedlining

TANDEM MASTER CYLINDER

Type : AS/AS Tandem Vertical Split

Bore Size : 23.81 (15/16”) dia

Stroke : 33 mm

Split : 15 mm Primary 18 mm Secondary

Type of : Flangemounting

Reservoir : Non-integral polypropeylenereservoir coupled to the mastercylinder.

VACCUM BOOSTER (YELLOW HOUSING)

Dia. : 254 mm (10”)

Boost ratio : 5:1

Stroke : 33 mm

Working pressure : 0.2 bar absolute

VACCUM BOOSTER(ZERO DEAD STROKE-DOUBLE DIAPHRAGM)(BLACK HOUSING) (if fitted)

Dia. : 254 mm (10")

Boost ratio : 6.7 : 1

Stroke : 33 mm

Working pressure : 0.8 kg/cm2 absolute

LCRV (LOAD CONSCIOUS PRESSUREREDUCING VALVE)

Ratio : 2.78 : 1

Fitted on rear brake circuit

Brake fluid : SAE J 1703f - DOT4

System capacity : 0.5 ltr

9

BRAKES

TIGHTENING TORQUES

Sr. No. Description Torque in kg-m

1. Booster mounting bolt to firewall 2.1 - 2.5

2. Mounting nuts of master cylinder to vaccum booster 1.0 - 1.6

3. All brake pipe line joints (coupling nuts) 1.4 - 1.8

4. Front caliper, retaining bolt to steering knuckle 6.8 - 9.0

5. Front caliper carrier retaining bolt 3.1 - 3.5

6. Front brake hose mounting (banjo) to caliper 2.5 - 2.8

7. Front caliper bleed screw 0.55 - 0.8

8. LCRV mounting screw on chassis bracket 2.1 - 2.5

9. LCRV linkage to bracket on axle 1.1 - 1.4

10. Rear brake assembly to dust shield 3.7 - 5.5

11. Rear brake hose to wheel cylinder 2.5 - 2.8

12. Rear wheel cylinder bleed screw 0.55 - 0.8

13. Rear wheel cylinder mounting to brake plate 0.54 - 0.68

14. Parking Brake cable / brake pipe line clamp to shell 2.1 - 2.5

15. Parking brake lever mounting on shell / floor 2.1 - 2.5

16. Wheel mounting nuts 12 - 15

10

BRAKES

FRONT DISC BRAKES

Front disc brakes are fitted with Colette Type C 57 Single Pot Calipers.

SALIENT FEATURES OF DISC BRAKES

Fig. 2 - Exploded view of caliper assembly (Brakes India make)

Disc brakes with higher thermal capacity are moresuited for modern vehicles, which can take careof higher braking torques needed with higherspeeds.

C 57 is the latest in Caliper design from Girling,which has a minimal corrosion of sliding membersand can offer uniform pad wear on either sideof disc.

Colette Caliper Assembly consists of a Caliperbracket bolted to stub axle and the body assemblyslides on two sliding pins fixed in the bracket.

Sliding pins are sealed against corrosion by dustcovers there by avoiding possible unequal slidingloads caused by dirt, corrosion.

Drag of the pads is taken directly by bracket.Consequently the pins are only loaded by theweight of body assembly.

CALIPER OPERATION

When brake pedal is pressed, hydraulic pressurefrom master cylinder pushes the piston and withit the in-board pad on to the disc.

Body assembly reacts and slides on sliding pinsto bring out-board pad into contact with disc.Clamping forces on both sides of disc thusbecome equal.

When hydraulic pressure is released, sealing ringfitted in the grooves of the cylinder retracts thepiston by a small amount which allows movingparts to relax sufficiently for the disc pads toretract and remain in close proximity to disc.

1. BODY ASSEMBLY2. SEALING RING3. PISTON4. BOOT5. BOLT6. SLIDING PIN7. BOOT8. BRACKET9. ASSEMBLY. PAD & SPRING10. ANTI RATTLE CLIP11. BLEED SCREW12. DUST CAP13. BRAKE DISC

13

11

BRAKES

CLEARANCE CORRECTION

When fluid pressure is applied on piston, it movesforward. Rubber seal, which exert pressure againstpiston, is fixed into grooves in the caliper. Hencethe shape of rubber seal is distorted at the I.D.

When pressure is withdrawn from brake pedal andfluid pressure is released from piston, a restoringforce is generated by seal and is pushes the pistonback to its original position.

As the pads wear, clearance between disc andpads becomes larger. Hence the piston has tomove a larger distance. Seal then could change inshape further but, since it is fixed into the groovesin cylinder, distortion is limited to same amount aspreviously described. Due to this, piston movesfurther to cover distance of clearance relative toseal in case.

When pedal is released, piston returns by samedistance and rubber seal recovers its shape asdescribed above.

Thus the clearance between the disc and pads aremaintained automatically. Caliper brake needs noadjustment.

BRAKE MAINTENANCE :

BRAKE ADJUSTMENT :

Disc brake is of self adjusting type. Needs noadjustment.

SERVICING :

Check pads for wear at specified intervals and fitnew pads when lining and metal pad thicknessmeasured together is 7 mm.

An indication groove is provided at the centre offriction pad. If it is vanished, that is the indicationfor changing pad. Caliper should be overhauled atspecified intervals.

FITMENT OF NEW PADS :

Jack up and remove both front wheels. Inspectpads for wear. If they are found to have worn,proceed as follows to replace them.

Loosen and remove bottom sliding pin retainingbolt, holding guide pin head.

Swing up the caliper and hold it with one hand.Remove both pads one by one.

Measure lining and metal pad together with avernier. If thickness is less than 7 mm anywherein pad, replace pads.

CAUTION :

Mark friction pads for their positions duringremoval. If pads have to be reused, install themat respective locations.

Alway use genuine pads for replacement.

Do not contaminate pad surface with grease or oil.

NOTE :

If you find any difficulty in swinging the caliper up,after removing the guide pin retaining bolt, it maybe necessary to push the caliper plunger backalong with the pad, using a screw dirver, afterloosening the bleed screw.

But make sure to bleed the system if pedal isfound spongy after replacing the pads.

INSPECTION :

Thoroughly clean the disc. If found scored,recondition the disc as per instructions.

Check condition of rubber boots for caliper piston& sliding pin.

If there is no visible deterioration in piston rubberboot and sliding pin rubber boot, new pads can befitted.

Check condition of anti rattle clips. If found OK,same clips can be reused after cleaning.

Insert both pads in between carrier and disc in theaxle so that friction material faces disc.

After inserting push both pads against disc withboth hands and swing down the caliper and fitbottom sliding pin bolt.

Tighten retaining bolt to a torque of 3 to 3.5 kgmby holding the guide pin.

Rotate the disc and make sure it is free to rotate.If it is not free to rotate, inspect and make surethat the pads are sitting square with the discwithout any tilt.

Follow same procedure for the other front wheel.

NOTE :

Caliper assembly make BI TVS & KBX are usedin selection. In case the pads are fitted with antisqueal shim, they have to be fitted back whilechanging pads. Please note the positions of antisqueal shims during dismantling, so that they canbe fitted back in correct location.

12

BRAKES

Fit wheels, jack down the vehicle.

CAUTION :

Apply brake couple of times with engine runningbefore taking vehicle for a road test.

Before applying heavy brake, it is advisable toapply brake gently several times at 50 kmph toallow brake pads to align.

Heavy braking or prolonged braking should beavoided in the initial 100 - 150 km of run until thenew pads are bedded.

Always replace all four pads at a time. Mixingof old and new pads strictly prohibited

DISMANTLING OF CALIPER : (BI TVS)Jack up and remove wheels. Disconnect hose fromchassis anchoring point and block bundy pipe withbleed screw dust cover to prevent loss of brakefluid.

Remove pads by swinging the caliper. Caliper canbe taken out from carrier by sliding the caliperbody towards inboard of disc. Take out theremaining sliding pin left in the carrier by releasingthe guide pin boot from the carrier. Remove hosefrom caliper body by taking out the banjo bolt.

After cleaning the surfaces, remove rubber boot forcliper piston from caliper body & piston by pullingthe same with fingers.

Keep a wooden piece in between the plunger andthe caliper body and blow compressed air into thecaliper gradually through the inlet port. Now youwill observe the plunger coming out of the calipergradually.

Remove sealing ring from the groove in the caliperhousing by using a thin blunt screw driver, takingcare not to damage the bore. Remove the bleedscrew from caliper body.

NOTE :

1. Take care to avoid puncturing of the dust bootwhile removal. Replace punctured boot.

2. Do not apply high compressed air, which willcause piston to jump out of the cylinder. Itshould be taken out gradually with moderatelycompressed air about 2 bar.

3. Do not place your fingers in front of piston whenusing compressed air.

INSPECTION

Clean all parts thoroughly with fresh brake fluid.Never use mineral oil like kerosene, petrol, dieseletc. After thoroughly cleaning, examine all partsfor damages and corrosion.

PLUNGER :Outer surface should be free from nicks, score orrust and should be smooth to touch. Caliperhousing bore should be free from score, pitting,corrosion and should be smooth to touch. The sealgroove in the bore should be there at the edges.

If the above conditions are satisfactory then kitreplacement will give satisfactory performance. Ifnot the caliper assembly should be replaced.

Do not use emery paper on piston surface.

SLIDING PINS :

Should be free from rust and bends and guide pindust covers should be soft and free from cracksor puncture. If in doubt, replace them.

PISTON SEALING RING :

Piston sealing ring is used to seal piston andcylinder and it is used to adjust the clearancebetween pad and disc. Replace the piston sealingring with a new one at every overhaul. Fit pistonsealing ring into groove in the cylinder taking carethat it should not be twisted.

ASSEMBLY OF CALIPER : (BI TVS)

Dip the plunger seal in fresh brake fluid and fit iton to the groove in the cylinder bore. Smear freshbrake fluid to the bore and on plunger surface.Assemble dust cover on to the plunger byreversing the dust cover. Now push the plungergradually into the bore until it reaches the bottom.

Fit the other end of the dust cover on to thecaliper body. Smear sliding pins with special redrubber grease. Insert the loose guide pin into thetop hole of the bracket and fit the dust cover onto the carrier. Now fit the caliper assembly to thecarrier in the reverse order of removal.

13

BRAKES

CALIPER ASSEMBLY - KBX MAKE

Specifications –

Bore Dia. – 57 mm

Friction pad Grade – R 802 ( Asbestos Free )

Type – Single Piston Floating Caliper

These disc brakes have more braking efficiency& higher thermal withstanding capacity & aresuitable on vehicles like Telcoline range of vehicleswhere the operating speeds and required brakingtorques are very high. These are self adjusting typeand hence do not require brake adjustment afterpad wear.

The clamping force exerted by the pads on bothsides of the disc is equally distributed by virtue ofit’s design, which results in uniform wear on boththe pads .

Since the caliper assembly along with disc is very

1. CALIPER ASSEMBLY2. BRACKET MOUNTING

BOLT3. PAD4. BOLT PIN5. CALIPER PISTON6. SLIDING PIN7. RATTLE CLIP/SPRING8. BOOT PISTON9. SLIDING PIN BOOT10. BRACKET11. SEAL PISTON12. BLEED SCREW13. DUST CAP

EXPLODED VIEW CALIPER ASSEMBLY - KBX MAKE

much exposed to atmosphere the heat dissipationis much faster compared to that of drum brakeswhich results in consistent braking performance.

1. Construction & Working —

The Disc Brake consists of a carrier and caliperbody. The carrier is mounted on the stub axle bymeans of two mounting bolts and the housingslides on two guide pins (6) also called as slidingpins fixed on the carrier. Two pads (3 & 3A) one onthe piston side and other on the opposite side arefitted and are held by the pad spring. The pads arealso guided over the anti rattle clips / spring (7)fitted on to the carrier. An anti-squeal shim is fittedon outboard pad which helps in dampening thesqueal noise.

The sliding pins are well protected from dirt , waterentry and corrosion by means of boot, pins (9) andthereby avoiding improper sliding loads caused dueto dust entry. The bore of the caliper housingaccommodates a piston (5) and a seal- piston (11)

11

1

2

3

4

5

6

7

7

8

910

9

4

6

12

13

Fig. 2a - Exploded view of caliper assembly (KBX)

14

BRAKES

whose cross section is square in shape. The sealis fitted in to the groove in the bore and the pistonslides thro the ID of the seal with certain amountof interference. Dust or water entry inside the boreis protected by Boot – Piston (8).

When the brakes are applied the hydraulic pressurefrom the TMC makes the caliper piston to moveforward and thereby the piston side pad also movesforward till it touches the rotating disc face. Thenfurther movement of the pad results in reactiveforce, which makes the caliper body to slide on thesliding pins to bring the opposite side pad incontact with the disc. Due to this reaction effectthe forces acting on both the pads remains equalalways.

When the brakes are released , the pressure in thesystem drops and the sealing ring inside the boreretracts the piston by a small amount . This makesthe pads to get free from the disc face , howeverremains in close proximity to the disc.

2. Maintenance & Overhauling —

2.1 Fitment of New Pads –

Apply hand brakes to prevent vehicle from rolling.Jack up the front axle and remove both the wheels.Inspect the pads through the inspection window andif found worn out replace them with the new set asper the following procedure.

1. Insert a screw driver between the outerpad backplate and the caliper housing andpush the screw driver outwards to push thepiston inside the caliper bore.

2. Loosen and remove the bolt - Pin (4) of thesliding pin. Swing up the caliper and byholding it, remove the pads one by onefrom its position.

3. Replace the old pads (3 & 3A) with thenew ones assembling the anti-squeal shimon outer pad and swing down the caliperand retighten the Bolt - Pin (4) with atightening torque of 2.2 to 3.2 Kgm. Oldanti-squeal shim can be reused if it is notdamaged.

4. After tightening, rotate the disc and ensurethat the disc is free to rotate. If not checkwhether the pads are sitting square with thedisc or for any abnormality in pad seating.

5. Repeat the above procedure for the otherside caliper.

Note :

Always replace all four pads at a time.

If the pads are to be reused make sure they areassembled back in the same position as they werewhen removed ie , piston side pad on to the pistonside and outer side pad on to the outer side. Thisis possible only when at the time of removal thesepads are marked for their positions and kept aside.

Never to lubricate the pad seating areas as thismay lead to jamming.

After assembly of pads , apply brake pedal 5 to 6times in static condition in order to make the padsalign properly.

It is recommended to apply light braking stopsduring road test and avoid heavy and continuousbraking during the initial 200 kms of run or until thenew pads are bedded.

Anti squeal shim should be put on outer side padalways.

2.2 Servicing of Caliper (KBX) –

2.2.1 Dismantling —

1. Apply hand brake and if necessary placewedges at the rear wheels in order toprevent the vehicle from rolling. Jack up thefront of the vehicle and remove the frontwheels by loosening / removing the wheelnuts.

2. Disconnect the hose from the caliper byremoving the banjo bolt .

3. Loosen and remove the bottom retainingbolt of the sliding pin(4). Swing up thecaliper and by holding it, remove the padsone by one from its position. Now removethe top retaining bolt of the sliding pin (6)and remove the caliper.

4. Clean the caliper externally with alcohol orfresh brake fluid. Remove the caliper piston(5) from the bore by blowing drycompressed air through the inlet port of thecaliper. Remove the boot (8).

5. Then by using a blunt edged connector orscrew driver, remove the seal- Piston (11)

15

BRAKES

from the groove. While removing the sealcare to be taken not to damage the bore.Then remove the bleed screw (12) from thecaliper body.

6. All the removed parts should be cleanedproperly using fresh brake fluid or alcoholand kept in a clean tray.

NEVER USE ANY MINERAL OIL BASEFLUIDS LIKE KEROSENE, DIESEL, PETROLetc,. FOR CLEANING OF REMOVED PARTS.

7. Remove the sliding pins (6) from the carrieralong with the sliding pin boots (9). Thenseparate the boots from the sliding pins.Ensure the sliding pins are without anybends or damages and their bores to befree from corrosion.

8. After thorough cleaning ensure that thepiston (5) is free from any damages, scoremarks on it’s outer surface. Also the caliperbore must be free from score marks,corrosion / pitting and the sealing ringgroove in the caliper should be free fromdamages. If these parts are found perfectlyacceptable, then the caliper can beoverhauled with the new repair kit.Otherwise the whole caliper should bereplaced with a new one.

2.2.2 Assembly —

1. The Piston seal (11) is to be lubricatedwith fresh brake fluid and assembled in tothe seal groove in the caliper bore. Makesure the seating of this is properly done.Then lubricate the outer surface of thepiston (5) with fresh brake fluid.

2. The lips of the piston boot (8) to besmeared with the special red rubber / BN2grease before it is assembled . Locate theouter lip of the boot on to the boot groovein the caliper and ensure firm location ofthe boot lip in the groove.

3. Stretch the Piston end of the boot byfingers & insert the caliper piston into theboot & push it gently into the bore. Oncethe piston is home , ensure the fitment ofthe boot on to the boot groove on thepiston. The piston should be inserted intothe bore in a straight position only. If it

gets tilted while pushing, there is a chancethat the piston will get jam half way & alsocan damage the seal.

4. Smear the sliding pins (6) and the slidingpin bore with BN2 or special red rubbergrease. Fit the sliding pin boots (9) on tothe pins and assemble it on to the carrierbore. Ensure proper location of the boot lipon to the carrier. Move the pins in and out3 to 5 times in order to allow for thetrapped air inside the bore to escape.

5. Now fit the caliper body to the carrier in thereverse order of removal and repeat theabove procedure for the other side & bleedthe vehicle .

During the assembly of caliper the followingpoints are to be ensured —

The braking surface on brake disc should be freefrom score marks. Thickness , runout and faceoutof the disc to be within the prescribed limits.

Bleed screw to be torque tightened to 1.0 to 1.2Kgm

Banjo bolt to be torque tightened as per vehiclemanufacturers specification. Use of new copperwashers is highly recommended.

In case the carrier is removed from stub axle, thenthe mounting bolts to be checked for its tighteningtorque as per vehicle manufacturer’s instructions .

16

BRAKES

DISC INSPECTION :

Before assembling the caliper back to the carrier,the disc should be inspected.

The disc should be free from score marks. Ifscores are found, this should be ground andrefitted. But at no time more than 0.25 mm (0.010”)material should be ground per side. If the totalthickness of the disc after grinding is found to beless than 19.00 mm, the disc should be changed.After fitment, the face run out of the disc shouldbe less than 0.1 mm (0.004”). Otherwise pedalpulsation will be felt during brake application.

The disc thickness variation to be checked bymeasuring the thickness of disc at 4 or morepoints around the circumference of disc.

All measurements must be made at the samedistance from edge of the disc. During themeasurement confirm that the dial gauge probe tobe approx. 10 mm from the outer edge of the discand perpendicular to disc with slight pre load.

Check front wheel bearing for looseness beforeface run out measurement. The control of thebraking surface finish is necessary to avoid pullsand erratic performance. It will also help inextending pad life.

Fit the bottom guide pin dust cover’s other end tocarrier. Fit new pads as explained earlier andcheck for the gap of 21.4 mm minimum, asexplained under “Fitment of New Pads”. Swingback the caliper to its place and fit guide pinretaining bolt and tighten to recommended torque(3.1 to 3.5 mkg).

Fit bleed screw and tighten to a torque of 0.55 to0.8 mkg; connect banjo end of the hose withcaliper body by fitting banjo bolt using new copperwasher. Before fully tightening the banjo bolt, makesure that the other end of the hose is anchored tothe chassis end. In this condition the hose shouldbe free from twists. Tighten the banjo bolt to atorque of 3 to 4 mkg. Connect pipe nuts to thefemale end of the hose after removing the dustcap from the bundy tube and tighten.

Caliper carrier mounting bolts to be checked for itstightness to a torque of 6.3 to 8.3 mkg.

The other side of the caliper can be serviced inthe same way.

Bleed the brake system as per procedure given onpage 23.

If bleeding equipment or power bleeding is used tobleed the system, which does not necessitateapplication of pedal, you must make sure severalbrake pedal applications are made to maintainminimum clearance between pad and the discbefore taking the vehicle for road test.

HOSE REPLACEMENT

Hoses should be replaced as per recommendedschedule.

Check hoses/pipes for leak/crack/damage. Replaceif necessary.

NOTE :

Disc brake assemblies of BI TVS & KBX makesare used in selection.

Individual components, brake pads, calliper repairkits etc. for both makes are different & notinterchangeable with each other.

Please ensure to use appropriate make of itemsduring repair/overhaul.

17

BRAKES

REAR DRUM BRAKES1. ASSEMBLY. BACK PLATE2. ASSEMBLY. LINED SHOE LEADING3. ASSEMBLY. LINED SHOE TRAILING4. SPRING5. PIN6. HAND BRAKE LEVER7. SPRING PLATE8. RETAINING PLATE9. SPRING

10. ASSEMBLY. STRUT11. PIN12. CUP WASHER13. SPRING14. SEAL15. PISTON16. DUST COVER17. BLEED SCREW18. DUST COVER19. GASKET20. ADAPTER21. WASHER22. SET SCREW23. WHEEL CYLINDER24. SPRING

DESCRIPTION

Hydraulic non-servo sliding shoe brake (HNSS)is of the leading/trailing shoe type. It is simplein design, robust in construction.

Sliding shoe arrangement provides high brakingefficiency, and allows shoes to centralisethemselves automatically with brake drum to giveuniform lining wear.

Shoe return springs are fitted between shoes toprovide a positive shoe retraction. This avoidsany possibility of brakes ‘hanging on’.

To maintain shoes squareness with drum, bothshoe rims rest on pads formed at suitable placeson backplate.

Shoe is held against backplate by means of a shoehold down pin and spring. For independentadjustment of each shoe, two cam type adjustersare pivoted on the backplate. When adjuster stem

Fig. 3 - Exploded view of rear brake assembly.

23

24

is rotated in a clockwise direction, cam moves theshoe towards drum.

Wheel cylinder is double acting, and exerts equalforce on both shoes. Rubber gland seals retainthe fluid, and rubber boots fit around the pistonsover the ends of the cylinder to prevent dustand water entering the wheel cylinder assembly.

Hand brake operating lever is attached to trailingshoe by means of a pin retained in position byretaining plate. A strut connects the leading endtrailing shoes. A cable connects the pistol gripto the hook end of the operating lever. Whenhand brake is applied, operating lever pushesthe strut, forcing the leading shoe against drum.

Once leading shoe is against drum, furthermovement of lever pushes the trailing shoe. Arubber sleeve is provided on strut to preventrattling.

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BRAKES

BRAKE MAINTENANCE

The gap between the lining and the drum shouldbe checked at specified intervals through theinspection hole provided in the back plate, afterremoving grommet. If the gap exceeds 0.25 mm(0.010”) brake should be adjusted.

BRAKE ADJUSTMENT (Fig. 4)

Jack up rear axle, place chocks at front wheel andclear off ground. Keep gear shifting lever in neutralpoisition. Release hand brake.

Turn the hexagonal adjuster nut clockwise, untilthe shoe begins to bind on the drum. Turn theadjuster anti clockwise until the wheel gets rotatedfreely.

Repeat the same procedure for other shoe of thesame wheel.

Operate brake pedal two or three timessimultaneously rotating the wheel to allow theshoes to centralise in the drum.

Readjust if necessary until the wheel is just free.

Repeat the same procedure for the other wheel.

1) Linings should not be allowed to wear down torivet heads.

2) Clean backplate and lubricate the tips of theshoe platforms with graphite grease and themoving parts of the adjuster with mineralgrease at specified intervals. Keep greaseaway from shoe linings and all hydraulic parts.

3) Wheel cylinder should be overhauled atspecified intervals.

MAJOR OVERHAUL

It is essential that shoe linings are inspected atregular intervals to prevent drums beingpermanently damaged and subsequently makingdrum removal extremely difficult. If drums areallowed to become scored or grooved, problem ofdrum removal can usually be overcome byincreasing clearance between shoe linings anddrum.

REMOVAL OF SHOES

Jack up the vehicle. Remove the wheels, Slackenthe adjusters to keep the shoes in a completely

Fig. 4

retracted position. Remove the brake drum.

Push the hand brake operating lever away from theshoe rim and remove the cable from the operatinglever hook.

Using a ‘spring plier’ or a screw driver remove theshoe return spring at the wheel cylinder end.

Remove the shoe hold down pins from both theshoes by pressing down the spring and rotating thepin.

Remove both the shoes from the backplatealongwith the alongwith the abutment end spring.Slip an elastic band over the wheels cylinder toretain the pistons with the cylinder.

CLEANING

Clean the backplate thoroughly. Use a wire brushto remove any corrosion, but take care not todamage the rubber dust covers on the wheelcylinder.

Note : Never use petrol or kerosene, or paraffin etc.for cleaning brake parts as they are dangerous.

Ensure shoe-sliding platforms on the backplate aresmooth and not corroded. If necessary, Clean thefilings and apply a light smear of Graphite grease(high melting point grease) to each platform.

RELINING THE SHOES

Remove the rivets carefully. Before removingrivets, detach hand brake operating lever fromtrailing shoe. This may be done as follows :

19

BRAKES

Remove retaining plate from the pin groove bysliding with a screw driver. Remove spring plate.Lightly tap the pin to remove the operating leverfrom the shoe. If excessive wear on this pin isnoticed, it should be replaced.

While removing rivets, ensure that the holes in theshoe rim are not enlarged.

Clean the shoe rim to ensure a smooth evensurface for the lining.

Always use genuine linings and the rivets suppliedwith the relining kit.

Clamp the lining evenly to the shoe rim, and startrivetting at the centre and progress outwards to theend of the shoe. A flat ended anvil of the correctdiameter should be used against the rivet headand the tabular shank of the rivet should beproperly clinched.

Care should be taken, since overrivetting maycrack the lining. Ensure that no clearance existsbetween the lining and the shoe rim.

Fit the hand brake operating lever to the trailingshoe in the reverse order of removal.

Ensure that the spring plate convex side istowards the retaining plate.

Make sure the lever is free to operate.

Do not contaminate the lining surface with oil orgrease.

Refit the shoes in accordance with the followinginstructions :

FITTING SHOES

Clean the backplate. Check the backplate forgrooving or other damages. The pads must besmooth and not corroded. If necessary, smoothenthe pads with file or emery cloth, but do notremove any more material than is absolutelynecessary and note that each set of these padsis reduced equally. Clean off the metal filings.

New shoe retaining spring should always be fittedduring major overhaul.

Check the wheel cylinders for leaks by lifting theboot. Check the pistons for free movement. If aleak is suspected from the wheel cylinder or if thepiston movement is unsatisfactory the unit mustbe serviced. Refer to “Wheel Cylinder Servicing”.Inspect the wheel cylinder boots for cuts, cracks,hardening or other signs of deterioration. If in

doubt, the boot should be replaced.

Lightly smear vegetable based high melting pointgraphite grease on the backplate shoe pads and atabutment.

Do not use chassis grease.

Position the leading shoe (the shoe with the longerlining) on the backplate and fit shoe hold down pin,spring and washers. Ensure that the convex faceof each washer is towards the spring.

The leading shoe (The shoe with the longer lining)should be fitted towards the front of the vehicle.Hook the smaller spring at the abutment end(bottom) and the longer spring at wheel cylinderend of the shoe.

Position the trailing shoe (the shoe with the shorterlining and the hand brake lever) on to thebackplate and hook the smaller spring at theabutment end. Move the hand brake lever a littleand fit the shoe hold down pin, washer, spring andwasher, Position the strut between the leading andtrailing shoe webs.

Two slots are milled on either end of the strut. Oneof them is wider than the other. The narrow slotshould be on the leading shoe.

Ensure that the rubber sleeve on the strut is inposition and that the straight portion of the strut istowards the backplate.

Using spring plier, hook the longer spring on to thetrailing shoe.

While using the spring plier extreme care must beexercised as otherwise the lining may getdamaged.

Connect the hand brake cable to the operatinglever in the reverse order of removal.

Do not handle the lining more than it is necessaryand be sure that it is completely free from grease.

Centralise the brake shoes on the backplate,before fitting the drum, by lightly tapping in therequired direction.

Refit the drum and wheel.

Adjust the brakes as explained under “BrakeAdjustment”.

Check and correct the hand brake cableadjustment and road test.

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BRAKES

WHEEL CYLINDER SERVICING

OVERHAULING THE WHEEL CYLINDER

Wheel cylinder should be overhauled & replacedat specified intervals.

Wheel cylinder may be serviced using genuinerepair kit, if piston and wheel cylinder bore arein good condition.

REMOVAL OF WHEEL CYLINDER (REAR)

When removing or servicing wheel cylinders, itis necessary to drain the brake fluid from thesystem and remove the brake shoes.

Attach a bleed tube to the bleed screw, havingfirst removed its rubber dust cover. Unscrew thebleed screw 1/2 to 3/4 turn and pump out thefluid into a suitable container by operating thebrake pedal. Remove the bleed tube.

Remove the brake shoes as explained under“Removal of Shoes”.

Remove the adaptor from the feed port alongwith the gasket. Remove the wheel cylinder fromthe wheel cylinder mounting bolts and take outthe wheel cylinder from the backplate.

DISMANTLING OF WHEEL CYLINDER(BI TVS) (Fig. 5)

Clean the wheel cylinder externally. Remove thedust covers fitted on the wheel cylinder assemblyand the bleed screw. Push out the pistons, andsprings. Remove the seals from the pistons andclean all the parts thoroughly in fresh brake fluidor alcohol and place them on a clean sheet ofpaper.

Never clean the wheel cylinders of internal partswith kerosene or petrol.

EXAMINATION OF WHEEL CYLINDER(BI TVS)

Examine the cylinder bore and pistons. If theyare not scored, corroded or ridged and are smoothto the touch, new seals can be fitted. If thereis any doubt about the condition of the bore, anew wheel cylinder assembly must be installed.

If the system has been contaminated with mineralfluid of any type, the system should be flushedout with fresh Brake Fluid or Alcohol and allrubber parts including hoses should be replaced.

Fig. 5 - Wheel cylinder assembly1. Dust cover2. Piston3. Seal4. Spring5. Bleed screw

2 2

33

4

5

1 1

Contaminated seal may be identified by comparingit with a new seal (but do not let them touch).If the old one is appreciably larger, sealcontamination is indicated.

ASSEMBLY OF WHEEL CYLINDER(BI TVS)

1. Lubricate the bore liberally with fresh brakefluid. Dip new gland seals and pistons infresh brake fluid.

2. Assemble gland seals on to piston in sucha way that it fits squarely on piston stem(seal lip should be towards the thin collarof piston).

3. Assemble the spring on to one of the pistonstems.

4. Assemble piston assembly into cylinder borewith the spring leading into the bore carefullyeasing seal lip.

5. Insert other piston with seal from other end.6. Fit dust covers to wheel cylinder mouth and

piston.7. Fit bleed screw and tighten to specified

torque.8. Fit a rubber band around the piston to retain

them in the bore.Absolute cleanliness has to be maintained anda clean brake fluid must be used. Never usebrake fluid bled from the system.

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BRAKES

FITMENT WHEEL CYLINDER

Install wheel cylinder assembly on to thebackplate and secure with bolts and washers.Tighten wheel cylinder mounting bolts to a torqueof 0.54 to 0.68 mkg. Fit adaptor with a newgasket on to the feed port and tighten to a torqueof 2.5 to 2.8 mkg.

Remove rubber band from wheel cylinder. Refitbrake shoes as described under “Fitting Shoes”.

Connect the bundy pipe to the adaptor port.

Refit drum and wheel.

Bleed the system as per procedure.

Adjust brakes and road test.

NOTE :

Wheel cylinders make BI TVS and KBX are beingused in selection. Repair kits for both the makesare different & non-interchangeable.

Please ensure to use correct make of repair kitsduring overhauled.

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BRAKES

TANDEM MASTER CYLINDER (BI TVS)(Fig. 6)

DESCRIPTION

The AS/AS tandem master cylinder consists oftwo independent chambers in a single casting,housing primary and secondary plungers fittedwith gland seals having minimum friction.

Each hydraulic system is so designed that anyfailure of pressure seal in one of the systemswould not result in total failure of braking system,since the other system remains completelyoperational and ensures minimum safe brakingperformance.

The specific design feature of this master cylinderis that pressure is developed in both the chamberssimultaneously without any time lag.

Fig. 6 - Tandem master cylinder Sectional View (BI TVS)

STOP PINB A C K

SEAL

Under normal conditions when brake pedal isdepressed, booster output rod pushes primaryplunger of master cylinder. At the same time,force of primary spring moves secondary plungerforward.

Simultaneously recuperating pressure seals onboth plungers cover recuperating holes, developingpressure simultaneously in both chambers.

Pressurised fluid in primary chamber istransmitted to rear brakes and from secondarychamber to front brakes.

Fluid reservoir comprises of two separatechambers serving each system with a commontopping up connection at upper portion.

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BRAKES

OVERHAULING OFTANDEM MASTER CYLINDER

Master cylinder should be overhauled at specifiedintervals.

If condition of bore is satisfactory, overhaulingcan be done by using genuine repair kit.

Or else, a new cylinder assembly needs to befitted.

During overhaul, all internal parts includingplungers and springs should be replaced. withgenuine parts provided in the kit.

REMOVAL OF TANDEM MASTER CYLINDER

Connect a bleed tube to one of the rear wheelcylinder’s bleed screw and drain fluid into acontainer by pumping the pedal.

Repeat the same by connecting the bleed tubeto one of the front wheel cylinder’s bleed screwsand collect the fluid.

Disconnect all outlet pipes from master cylinder.

Loosen master cylinder mounting nuts andremove the same.

DISMANTLING OF TANDEMMASTER CYLINDER (BI TVS)

Clean tandem master cylinder assembly externallywith alcohol or fresh brake fluid before dismantlingit.

Hold the fluid reservoir and by rocking it on eitherside, lift the same out of the grommets in thetandem master cylinder.

Fig. 7 - Tandem master cylinder - Exploded view (BI TVS)

1. BODY

2. STOP PIN

3. GASKET

4. ‘O’ RING

5. SPRING SECONDARY

6. SPRING RETAINER

7. RECUPERATING SEAL

8. SEAL SHIM

9. SECONDARY PLUNGER

10. PRIMARY PLUNGER ASSEMBLY.

11. STOP WASHER

12. PRIMARY BACK SEAL

13. INTERMEDIATE RING

14. CIRCLIP

15. GASKET

16. SEAL (FLUID TANK)

17. ASSEMBLY. FLUID RESERVOIR

18. FILTER

19. RUBBER WASHER

20. ASSEMBLY. FILLER CAP

14

11

12

13

10 7 9

8 6 5 4 23

1 15

16

17

1819

20

24

BRAKES

Remove both the grommets from the mastercylinder body using a connector screw driver withblunt edge.

Remove the ‘O’ ring fitted in the groove on themounting flange with a blunt edged pin.

Slightly push the primary plunger with a roundrod, hold it in depressed position and removethe stop pin, with gasket.

Without removing the tandem master cylinder,the secondary plunger cannot be removed.

Remove the adaptor from the secondary outlet.

Then, clamp the cylinder (housing) in a vice withsoft jaws. With the help of circlip plier, removethe circlip.

Remove the complete primary plunger assemblyout of the bore.

Remove the stop washers intermediate ring andthe primary back seals out from the shaft ofthe primary plunger.

Remove the cylinder from the vice.

Tap the cylinder, bore facing downwards, on awooden block to allow the secondary plungerand the return spring to slide out of the bore.

Clean the cylinder bore in fresh brake fluid oralcohol and blow with compressed air.

Be sure that the four holes (two cut off holesand two feed holes visible through the primaryand secondary inlet ports) in the cylinder bodyare clean, by blowing dry compressed air.

Do not poke the holes with sharp instrument.

Blow breather hole at the flange and make sureit is clear.

INSPECTION OF TANDEMMASTER CYLINDER (BI TVS)

Examine the bore of the tandem master cylinder.

If it is not scored, rodged or corroded and issmooth to the touch, the master cylinder canbe re-assembled using the parts from the genuinekit.

If bore has deep grooves or pitting marks, fit anew master cylinder assembly.

If contamination is observed in the removed seals(normally they would have swollen and can be

compared with new seals from the kit which willtell clearly that the size is enlarged), the entiresystem, i.e. wheels cylinder rubber parts includingboth front and rear hoses must be discardedand the entire system should be flushed.

CAUTION :Do not use kerosene (or) petrol (or) any other mineraloils to clean the cylinder and its internal parts. As itwill lead to contamination and damage of rubber parts.Clean all dismantled par ts with alcohol orrecommended fresh brake fluid only.

ASSEMBLING TANDEMMASTER CYLINDER (BI TVS) (Fig. 7)

To facilitate easy assembly, smear the cylinderbore with fresh brake fluid liberally.

Dip the plungers and all seals in fresh brakefluid.

Fit recuperating seals in the secondary plungergrooves. The first seal lip facing the primaryplunger assembly and the lip of the second sealfacing the opposite side.

Push the seal shim recuperating seal on thestem side of the secondary plunger in such away that the lip of the seal faces towards thesecondary spring.

Fit the spring retainer in correct position and fitthe secondary spring.

Clamp the cylinder body with its mouth pointingupwards in a vice fitted with soft jaws.

Fit secondary plunger assembly with thesecondary spring leading into the bore using sealguide.

Then slowly push the plunger down the bore,with a round ended rod. Press it down fully andwhilst holding screw in the stop pin with a newgasket (stop pin) and tighten to a torque of 0.55to 0.7 mkg.

Slowly let the secondary plunger back till ittouches the stop screw.

Now insert the primary plunger assembly in thesame manner into the bore using the seal guide.

Fit the first stop washer on to the primary plungershaft.

Fit the primary back seal into bush and slidethe bush on to the primary plunger shaft withthe seal in the bush leading into the bore.

25

BRAKES

Press the bush firmly into the bore.

Insert guide on to the primary shaft. Whilstpressing down the guide remove the bush.

Remove the guide from the primary plunger shaft.

Insert intermediate ring on to the primary plungershaft.

Fit the second primary back seal into Bush andfit the seal on to the primary plunger shaft asdone earlier.

Fit the second stop washer on to the plungershaft.

Fit circlip by using a circlip plier.

NOTE :While fitting the primary back seals, make surethat lips of the seals are facing forward.

Actuate the primary plunger assembly for coupleof times and check for the quick return of theplunger.

Fit a new ‘O’ ring in the groove on the mountingflange of the body.

Fit grommet into both inlet ports by liberallylubricating the same with fresh brake fluid.

Fit fluid collection tray on to the fluid reservoiroutlets and position the same into the grommetsand slightly rocking them on to the either side,press it home.

NOTE :

It is essential that the reservoir filler cap must beremoved. The baffle and baffle cover taken outfrom its place and the breather hole in the cap iscleared and the baffle and the baffle cover refittedbefore fitting the filler cap on to the tank. It isadvisable to replace the rubber washer in the fillercap during every overhaul.

Now the tandem master cylinder is ready forfitment.Do not alter the height of the output push rodof the vacuum booster unit.

Tandem Master Cylinder is to be fitted back onto the vacuum booster in the reverse order ofremoval.

Tighten mounting nuts to specified torque.

Connect outlet pipes to master cylinder.

Tighten coulping nuts to specified torque.

Fill reservoir with recommended brake fluid andbleed the system.

Check for brake fluid leaks.

TANDEM MASTER CYLINDER (KBX) :

Fig. 7a - Tandem master cylinder - Exploded view (KBX)

26

BRAKES

ALUMINIUM TANDEM MASTERCYLINDER ASSEMBLY (KBX)

Type – Compensatory Port Type

Diameter – 23.81 mm

Primary Stroke – 15 mm

Secondary Stroke – 18 mm

Primary Connected to – RR . RH & LH

Secondary Connected to – FT. RH & LH

1. General –

This is a light weight master cylinder with heattreated Aluminium body & with bore anodized . Ithas rigid steel pistons & single static seal typedesign. There is no secondary piston stopper .

In this kind of Tandem Master Cylinder, TMC isattached to booster assembly with the help of nuts& bolts on its flange & plastic reservoir is insertedin to its inlet port , which has circular baffle tohouse float of level indicator switch which showsthe low fluid level of reservoir & vertical baffles areprovided in order to divide the brake fluid of thereservoir in two portions , one is for primary circuit& other is for secondary circuit. Fluid is circulatedseparately to primary port & secondary port ofTMC due to this division.

Tandem Master Cylinder consists of two pistons,four seals,two springs & spring seats. Out of whichtwo seals are fitted on secondary piston , one sealis fitted on primary piston & one seal is calledstatic seal which is fitted on cup retainer & TMCbody.

2. Operation –

2.1 Normal Operation –

Depression of the brake pedal forces primary pistoninside the bore , which in turn pressurizes thebrake fluid next to it & actuates rear ( RH ) & rear( LH ) brakes. Simultaneously secondary circuitgets operated & actuates another set of brakes infront ( LH ) & ( RH ).

2.2 One Circuit Operation Primary ( REAR – RH& LH ) Failure –

Depression of the brake pedal makes primarypiston to move inside the bore , but due to failureof primary circuit system can not hold the

pressure, also brake fluid next to it will not getpressurized . Still primary piston keeps on movingfinally compressing primary piston return spring.When the primary piston return is fully compressedthe secondary piston moves & pressurises front (RH ) & ( LH ) brakes.

2.3 One Circuit Operation Secondary (FRONTRH & LH) Failure –

In this case , the inward movement of the primarypiston has little effect in pressurizing the brakefluid in the primary circuit initially , because theinitial built up of pressure in the primary circuitcauses the secondary piston to promptly yield &move inward without much resistance as thesecondary has a leak. Very soon the secondarypiston touches the cylinder wall & hence stopsmoving forward. From this point onwards, thepressure starts building up in the primary circuitwhich actuates one set of brake.

3. Overhauling of Tandem Master Cylinder –

TMC should be overhauled periodically as specifiedby us. During the overhaul all rubber parts alongwith pistons, springs and other hardware partsshould be replaced with genuine KBX spare partsand kits. This should be done only if the conditionof the cylinder bore is satisfactory, i.e. free fromscore marks, ridges, pittings etc., Otherwise thecomplete TMC is to be replaced with a newassembly.

Before removing TMC from Booster take out all thebrake fluid from the reservoir with a syringe orattaching the bleeding pipe to Rear Brake & FrontCaliper Pump the brake fluid out from the brakelines.

3.1 Dismantling of the TMC (KBX) –

1. Hold the brake fluid reservoir and by rocking iton both sides, lift the same out of the rubbergrommets fitted on to the TMC ports.

2. Remove the rubber grommets from the TMCinlet ports with the help of a connector orscrew driver with blunt edge..

3. By slightly depressing the primary piston,remove the circlip.

4. Remove the primary and secondary pistons byslightly tapping the cylinder on a woodenblock.

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BRAKES

5. Remove the static seal, piston guide and theretainer from the primary piston with the helpof connector or screw driver with blunt edge.

6. Remove the secondary piston assembly bytapping the TMC gently on a wooden block.

7. Discard all rubber parts.

8. Clean all other parts using fresh brake fluid oralcohol and ensure these parts are kept in aclean tray or on a clean sheet of paper.

NEVER USE ANY MINERAL OIL BASE FLUIDSLIKE KEROSENE,DIESEL THINNER, PETROLetc,. FOR CLEANING OF REMOVED PARTS.

9. Ensure visually that the feed port holes (2compensating holes + 2 vent holes) are clear.Do not poke these holes with sharpinstruments.

3.2 Examination of TMC and Internal Parts –

Examine the bore of the TMC. If it is not scored ,ridged or pitted and smooth, if felt, the TMC canbe rebuilt with the genuine KBX spare parts kit. Ifin case of slightest doubt on the bore condition,like deep groves or score marks in the bore then anew cylinder assembly should be replaced.

Examine both the pistons for rust, ridges or burrs.Ensure both the plungers are in good condition,free from the above conditions.

If contamination is observed in the removed seals.(seals would have swollen and the size would haveenlarged compared to the new seals) ensure allrubber parts in the system including rear wheelcylinder seals, front wheel cylinder / caliper sealsand the front and rear rubber hoses must bediscarded and the entire system to be flushed withnew brake fluid.

3.3 Replacement of seal Kit –

After inspection of TMC bore & Pistons, if noabnormal wear or scratch marks , damage isobserved then TMC can be rebuild using MinorRepair Kit. If pistons are found defective then alsoTMC can be rebuild by using Major Repair Kit.

Follow the instructions given below forreplacement of Minor Kit —

1. Remove the Secondary Piston return spring &take out the primary seal.

2. By cutting the secondary seal remove it fromthe piston.

3. Unscrew the primary piston shoulder screw &take out Spring, Spring retainer, spring seat &Primary Seal.

4. Discard & destroy all old rubber seals. Washthe pistons & other parts thoroughly in freshbrake fluid.

5. Dip the new seals in fresh brake fluid for tenminutes.

6. With the help of appropriate mandrel assemblesecondary piston secondary seal in the correctdirection i.e. lip side of the seal pointingtowards primary piston.

7. Assemble the Safety washer, primary seal,spring seat & spring on Secondary Piston.

8. Assemble Safety washer, Primary seal, springseat, spring, spring retainer & shoulder screwon primary piston.

9. Hold this whole assembly, firmly press thespring down & tighten the shoulder screw tillthe shoulder touches the piston. Do not overtighten the shoulder screw. Cross check thetotal length of the piston.

3.4 Assembly Of TMC (KBX) –

1. Ensure the hands are clean and clear fromany mineral oil.

2. Dip the pistons and all rubber parts suppliedin the service kit in fresh brake fluid. Alsolubricate the TMC bore with fresh brake fluidfor easy entry of Piston Assemblies.

3. Insert the secondary piston assembly into thebore, with the spring end leading. Care must betaken to properly guide the seals into the boreand thereby avoiding any damage to the seals.

4. Assemble the Seal Retainer, Static Seal,piston guide to the primary piston assembly.

5. Insert the primary piston assembly into thebore, with the spring end leading.

6. Depress the primary piston and fit the circlip.Ensure the seating of the circlip squarely intothe TMC groove.

28

BRAKES

7. With the help of a hylum rod actuate theprimary piston couple of times to ensure thequick return of the piston.

8. Fit the fluid reservoir grommets after liberallylubricating the inlet ports with fresh brake fluid.Position the reservoir into the reservoirgrommets holding it slightly at an angle &press it inside the grommets.

ENSURE FITMENT OF SEALING RING IN THEGROOVE OF THE TMC BEFORE MOUNTINGON TO THE BOOSTER.

NOTE –

1. It is essential that reservoir cap must beremoved and cleaned.

2. After fitting TMC on to the vehicle / vacuumbooster, the outlet pipes are to be connectedand torque tightened.

NOTE :

Tandem master cylinders of BI TVS & KBX arebeing used in selection.

In both the makes we have TMCs with cast ironbody & aluminium body.

BI TVS : TMC with cast iron body is used innormal 10” vaccum booster.

TMC with aluminium body is used in normal 10”booster & in Zero dead stroke double diaphragmboosters.

Repair kits for cast iron version & aluminiumversion are different.

KBX : This make of TMC (cast iron version &aluminium version) are presently used only fornormal 10” vaccum booster.

Repair kits for cast iron version & aluminiumversion are same in KBX make.

In view of the above, please ensure to use correctmake/type of repair kit while overhauling TMC.

29

BRAKES

BLEEDING THE HYDRAULIC BRAKESYSTEM

The process of removing air from hydraulic pipeline and cylinders is known as ‘Bleeding’, andit is necessary whenever any part of the systemhas been disconnected, or the level of fluid inthe plastic container has been allowed to fallso low that air has been drawn into the tandemmaster cylinder.

PROCEDURE

Carefully clean all dirt around filler cap. Removefiller cap, fill the reservoir with fresh brake fluidto the lower edge of filler neck. Fig. 8. Beforecommencing bleeding at each bleed screw, removedust cap and clean thoroughly.

Disc brakes are bled first. Although they areclosest to tandem master cylinder, plunger boreare much larger than wheel cylinder bores.Therefore they contain a greater amount of fluid.

Attach bleed tube to left front caliper bleed screwand place other end of the tube in a clean glassjar containing sufficient brake fluid to submergethe end of the tube. Fig. 9.

It may be advantageous to bleed the entiresystem with engine running.

Open bleed screws by 1/2 to 3/4 of a turn,sufficient to allow brake fluid to flow freely.

Depress foot pedal slowly throughout full strokeof the pedal, and allow it to return to its stopslowly.

There should be an interval of 3 to 4 secondsbefore making next stroke.

This action should be repeated until bubbles ofair cease to appear at the end of the bleed tube.

Close the bleed screw immediately after the lastdownward stroke of the pedal.

Whilst the pedal is thus held, securely tightenthe bleed screw and remove the tube.

Replace the dust cap on the bleed screw.

Ensure that the fluid level in the tandem mastercylinder reservoir does not fall low enough tocause air to be drawn into the system, throughoutthe bleeding operation.

Fig. 8

Fig. 9

30

BRAKES

Repeat the same procedure on the right frontcaliper, left rear wheel cylinder followed by the rearright wheel cylinder. Fig. 10.

If bleeding of any cylinder continues withoutsuccess for a considerable time, it may be that airis being drawn in past bleed screw threads.

In such instances, bleed screw should be closedat the end of each downward stroke of the pedal,allowing the pedal to return fully to its stop beforere-opening.

Tighten the bleed screw finally after the lastdownward stroke of the pedal.

Replace the dust cap on the bleed screw.

After completion of bleeding, apply brake pedalhard and check for any leak at the joints andbleed screws.

Check brake pedal for sponginess. If foundspongy, repeat complete procedure of bleeding.

If pressure bleeding is done, engine need not run.But the sequence of bleeding operation should stillbe left front - right front - left rear and right rearonly.

ALWAYS USE RECOMMENDED GRADE OFBRAKE FLUID.

Do not use the fluid bled from the system forrefilling in to the reservoir.

CAUTION : Brake fluid may cause damage topaint. So make sure that brake fluiddoes not touch the painted surface. Incase brake fluid comes in contact withpainted surface, wipe immediately &clean the surface.

Set brake light switch dimensions 3 + 0.5 andtighten lock nut.

Brake Fluid Level Inspection :

After completion of brake bleeding check the brakefluid level in the reservoir. The fluid level should bebetween MIN & MAX level indicated on the brakefluid reservoir.

If the warning lamp glows during engine 'ON'condition replenish fluid to MAX line.

Never use a container which has been used formineral oil or which is wet. Always keep all brakefluid containers capped to prevent contamination.

Fig. 10

31

BRAKES

VACUUM BOOSTER (Fig. 11)

FUNCTION

To provide power assistance by boosting up themechanical effort on the attached hydraulictandem master cylinder using the pressuredifference between atmosphere and vacuum.

Fig. 11

DESCRIPTION

This assembly is installed between the brakepedal and the tandem master cylinder. Employingthe pressure difference between negative -pressure (VACUUM) developed from the vacuum

CONVENTIONAL VACUUM BOOSTER (Yellow-Housing)

32

BRAKES

assistance and check for free return of brakepedal.

If conditions 5 and 6 are not fulfilled, replacethe vacuum booster or repair kit.

REMOVAL

1. Place wheel chokes in front and behind thewheels to prevent movement of the vehicle.

2. Remove the brake pedal return spring.

3. Remove the fork pin of vacuum brake valve.

4. Disconnect the hydraulic lines.

5. Remove the tandem master cylinder.

6. Disconnect vacuum line connected to NonReturn Valve.

7. Remove the mounting nuts of vacuum brakevalve and remove the nuts.

DISASSEMBLY

1. Clean the exterior of the unit.

2. Remove the non return valve, grommet, gaiterand filter retainer.

3. Mark the position of front & rear housingto ensure proper orientation of tandem mastercylinder mounting studs in front housing withrespect to the rear housing mounting studs.

4. Place and position the unit in the disassembly/ assembly fixture 2651 5890 42 04 whilefixture is clamped on a bench vice.

5. Place and position the swivel block on thefront housing.

6. Tighten the fixture handle to rest on theswivel block. Avoid overtightening.

7. Rotate the rods and match the notches &dimples in line. Do not over rotate, otherwisethe assembly will get locked again. Ifloosening is difficult, loosen the handleslightly and then rotate the rods.

8. After the front housing gets unlocked loosenthe fixture handle slowly until the fronthousing gets separated fully.

9. Unfold the segment retainer and remove thepivot assembly.

10. Push in the operating rod assembly fromfork end and relieve the segments from pistongroove.

pump and atmosphere. The booster providesincreased force resulting in more effective brakingperformance. The servo mechanism, whichtranslates this auxiliary force into braking forceuses a mechanical type lever balance system.

SERVICE CHECK

a. Inspection

● Check the tightness of the mounting nuts(torque 2.5 mkg)

b. Operating tests

● Check for free movement of the pushrod without binding while applying /releasing brake.

● Check for vacuum leak in brakes applied/ released position and ensure that thepipe lines and joints are from leakage.

PROCEDURE FOR CHECKING

Check the Vacuum Booster as per the proceduregiven below :

1. Connect a Vacuum gauge between Vacuumpump and vacuum booster with the help ofa suitable T connector.

2. Bleed the hydraulic lines.

3. Apply and release the brake without vacuumassistance and check for free return of brakepedal. If not, check the brake linkage, brakelight switch adjustment and pedal returnspring. Replace the defective component ifnecessary.

4. Start the engine and note the vacuum inthe gauge. It should be minimum 0.6 barbelow atmospheric pressure. If it is less,check for leakages in the pipe line andcondition of vacuum pump.

5. CHECK OFF LEAK : Build up maximumvacuum in the vacuum booster. Switch offthe engine. With the pedal in releasedcondition, drop in vacuum level in 30 secondsshould be less than 0.03 bar.

6. CHECK ON LEAK : Build up maximumvacuum in the vacuum booster. Switch offthe engine. When the brake, further drop invacuum level in 30 seconds should be lessthan 0.05 bar.

7. Apply and release the brake with vacuum

33

BRAKES

11. Remove the diaphragm return spring,segments and the segment retainer.

12. Remove the operating rod assembly fromvalve body by pulling it out at the fork end.

13. Loosen and remove M6 set screw (10 A/F)four numbers from the value body.

14. Remove the spring guide, diaphragm discand diaphragm from valve body.

15. Press out the lip seal from rear housing.


1. Wash and clean all metal parts and blowdry with compressed air.

2. Inspect all the parts for excessive wear anddeterioration.

3. Check valve body piston bore and outerdiameter for any score mark / crack /damage.

ASSEMBLY (Ref. Figs. 12 and 13)

1. Use recommended repair kit and diaphragmto replace old parts found to be worn out /scored during inspection.

2. Lubricate all moving parts and ‘O’ rings(except diaphragm) with grease suppliedalongwith repair kit.

Fig. 12 - Vacuum brake valve (Exploded view)

COMPONENTS

1 NON RETURN VALVE 8 SEGMENT RETAINER 16 FILTER

2 RUBBER GROMMET 9 SCREW 17 FILTER

3 FRONT HOUSING ASSEMBLY 10 SPRING GUIDE 18 REAR HOUSING ASSEMBLY

4 DIAPHRAGM RETURN SPRING 11 DIAPHRAGM DISC 19 LIP SEAL

5 SPHERICAL END PIECE 12 DIAPHRAGM 20 FILTER RETAINER

PIVOT ASSEMBLY COMPRISING 13 VALVE BODY 21 NUT

6 PUSH ROD ASSEMBLY 14 SEALING RING 22 GAITER

7 SEGMENT 15 OPERATING ROD ASSEMBLY

12

3 45

6

7

89

10

11

1213

14 1516

17

19

20

18

2122

34

BRAKES

3. Press in the lip seal in the rear housing usinga soft mandrel and ensure that the lip sealseats on the rear housing properly. Use awooden mallet to tap the seal into the housing.

4. Pack adequate grease in the lip seal.

5. Place and position the diaphragm, thediaphragm disc and spring guide on the valvebody

6. Secure the above onto the valve body usingM6 set screws by tightening to a torque of1 mkg. Use Loctite 242 or equivalent onthe screws lightly before fixing them ontothe valve body.

7. Assemble ‘O’ ring on the piston groove ofoperating rod assembly.

8. Drop the valve body in the rear housing boreand insert the operating rod assembly in thevalve body.

9. Check the segments and pivot plate forproper orientation and assembly.

10. Ensure that there are two solid coils belowboth the segments as shown in Fig. 14.

11. Push in the operating rod allowing the pistonto come out from valve body, so that thegroove on piston protrudes out adequatelyto assemble the segments in the groove.Pull out segments slightly upward and checkfor proper seating.

12. Fold the segment retainer and secure thepivot assembly together.

13. Place the rear housing assembly with valvebody and operating rod assembly securedwith pivot assembly and diaphragm returnspring on the fixture.

14. Locate the diaphragm on the rear housingand ensure proper seating of the diaphragmouter bead in the rear housing shell. Applyfrench chalk powder on the diaphragm surfaceand its outer beading.

15. Place and position the front housing on thereturn spring and match its notches with thedimples provided in the rear housing. Ensurethat the marking made during dismantlinglies closely apart.

16. Tighten the fixture handle simultaneouslyaligning the notches of front housing and

dimples of rear housing in line. Continuetightening to allow the front housing to movefreely and contact the diaphragm.

17. Rotate the rods uniformly without jerk toavoid twisting of diaphragm and lock thehousing and match the marking.

18. Avoid grease / oil from diaphragm duringassembly.

19. Loosen the handle and remove the unit fromthe fixture.

20. Assemble the grommet, non return valve,filter retainer and gaiter. Ensure gaiter islocated properly on both ends.

21. Mount the unit on the vehicle and connectbrake pedal return spring. Adjust pedalposition and free play.

22. Connect the vacuum pump line with the nonreturn valve of vacuum brake valve.

23. Mount the master cylinder on the vacuumbrake valve and connect the hydraulic lines.Bleed the hydraulic system.

Fig. 13

35

BRAKES

Pist

on

Dia

phra

gm

Ope

ratin

g R

od A

ssem

bly

Non

-Ret

urn

Val

ve

Rea

r H

ousi

ng

Lip

Sea

l

Pist

on

ZER

O D

EA

D S

TRO

KE

DO

UB

LE D

IAP

HA

RM

VA

CU

UM

BO

OS

TER

(B

lack

-Hou

sing

) (I

F FI

TTE

D)

Fig. 14

36

BRAKES

ZERO DEAD STROKE DOUBLE DIAPHRAGM VACUUM BOOSTER

Fig. 15 Exploded view double diaphragm vacuum booster

37

BRAKES

DOUBLE DIAPHRAGM VACUUM BOOSTER PARTS

N0. PART NAME

1. Fork

2. Gaiter

3. M10* 1.5 ISO Nut

4. Retainer

5. Filter

6. Filter

7. Rear Housing

8. Retainer

9. Spacer

10. Retainer

11. Key Retainer

Operating Rod Sub Assy.

12. Operating Rod

13. Spring Retainer

14. Retainer spring

15. Spring

16. Spring seat cup

17. Valve Rubber cup

18. Piston

19. Seal

20. Diaphragm

21. Diaphragm Disc

22. Cover

23. Cover

24. Seal

25. Seal Retainer

26. Retainer

N0. PART NAME

27. Diaphragm

28. Diaphragm Disc

29. Valve Body

30. Key

31. Bush

32. Rubber Reaction Disc

33. Push Rod

34. Push Rod Retainer

35. Spring

36. Front Housing

37. Rubber Grommet

38. Non Return Valve Assy.

39. M8*1.25 Hex Nut

40. Gasket

41. Sealing Ring

42. Spacer

43. Stud

44. Sealing Ring

38

BRAKES

ZERO DEAD STROKE (ZDS) DOUBLE DIAPHRAGMVACUUM BOOSTER

ADVANTAGES OF ZDS BOOSTER :a. Lower dead stroke

b. Lower overhaul stroke

c. Lower pedal force

d. Lower force requried to start braking action

All this lead to improved pedal feel.

1. FUNCTION :

To provide power assistance by boosting upmechanical effort applied at the brake pedal onthe hydraulic master cylinder attached to it, usingvacuum. The vacuum brake valve operates onthe pressure difference between vacuum andatmospheric air.

Fig. 16

Fig. 17

39

BRAKES

2. DESCRIPTION (Fig. 41):This assembly is installed between the brakepedal and the master cylinder. Employing thepressure difference between the vacuumdeveloped by the vacuum pump and atmosphericpressure, the vacuum brake valve amplifies theinput force on the brake pedal resulting in moreeffective braking performance. Theservomechanism, which converts this input forceinto braking force, is a rubber reaction disc typebalancing system.

3. CONSTRUCTION (Fig. 41 & 42):The assembly mainly consists of twodiaphragms, sheet metal pressed front and rearhousings, cover, valve body, operating rodassembly, push rod, key and rubber reaction disc.The 9” diaphragm’s outer bead is clampedbetween the front and rear housing and its innerbead is mounted on the valve body. The 8”diaphragm’s outer bead is clamped between fronthousing and cover and its inner bead is retained

Fig. 18

inside the diaphragm disc. The operating rodassembly consists of piston, valve rubber cup,operating rod, and valve retaining spring andoperating rod return spring. This operating rodassembly is positioned inside the valve bodyby means of key. The rubber reaction disc ishoused inside the push rod, which is retained inplace against the valve body by the diaphragmreturn spring which is resting on the springretainer. The assembly consists of four chambersnamely 1,2,3 & 4 as in figure 2. In all conditionsof operation, the chamber 1 and 3 will always beconnected through passage A in the valve bodyand chambers 2 and 4 will be connected throughanother passage B in the valve body, as shownin figure 2. There is a vacuum passage C in thevalve body, which connects the chamber 1 withchamber 4. The 8” diaphragm acts as a sealbetween chambers 4 and 3, while the 9”diaphragm acts as a seal between chambers 1and 2.

Fig. 18a Fig. 18b

40

BRAKES

Fig. 19

5. OPERATION:

5.1 Released or normal running position (Fig.44):When the brakes are released, the vacuum brakevalve is in released position. The valve body,operating rod sub-assembly, diaphragms anddiaphragm discs are positioned towards the rearhousing side due to the fitted load of diaphragmreturn spring. Both the vacuum valve (X) and airvalve (Y) are in closed condition. Vacuum isapplied to the vacuum brake valve, through thenon-return valve in the front housing. Vacuum iscommunicated from chamber 1 to chamber 3through the passage A and to chamber 4 throughvacuum passage C. From chamber 4, vacuumis communicated to chamber 2 through thepassage B. There is constant vacuum in all the4 chambers, in the normal running condition. Asthe diaphragms and valve body are pushedtowards rear housing by the diaphragm returnspring, no force is transmitted to the mastercylinder in this condition.

TO VACUUM

4. ZERO LOST STROKE (Fig. 43):From Fig. 43(a), we can see that the operatingrod sub-assembly is attached to the valve body,by means of key. Due to the opposing force ofoperating rod return spring, the key is pulledtowards the operating rod side, in the sub-assembly, keeping the vacuum valve (X) open.But when the valve body sub-assembly is fittedin the full assembly Fig. 43(b), the fitted force ofdiaphragm return spring pushes the valve bodytowards the rear housing, till the key butts againstthe rear housing. This movement of the valvebody, results in the closing of the exhaust travel,thereby closing the vacuum valve andsometimes even opening the air valve (Y). Onapplication of the vacuum, the valve body movesforward just enough to close the air valve (Y)and bring the assembly to a balanced condition.Hence, at normal running condition, both thevacuum and air valve are closed. This featureprovides output force at nearly zero lost strokeof the operating rod.

41

BRAKES

Fig. 20

5.2 Brakes applied condition (Fig. 45):When the pedal is depressed, the operating rodis pushed in. The piston moves away from thevalve rubber cup, opening the air valve (Y),thereby communicating atmospheric air tochamber 4 and to chamber 2. Fig. 45. This resultsin presence of air in chambers 2 & 4. During thistime the vacuum valve (X) is closed and vacuumis retained in chambers 1 & 3 resulting in apressure difference from those in chambers 2 &4. This pressure difference results in net forceacting towards the front housing side resultingin transfer of force to the master cylinder throughthe push rod.

42

BRAKES

Fig. 21

5.3 Balancing (Fig. 46):

When the output force is conveyed through thepush rod to the master cylinder, the reaction forcefrom the master cylinder comes on the rubberreaction disc and pushes it backwards. Thiscauses the valve body to traverse back and thepiston to contact the valve rubber cup, therebyclosing the air valve (Y) and vacuum valve (X).In this condition both the vacuum andatmospheric valves are closed. As a result, thereis a fixed pressure differential between chambers2 & 4 and chambers 1 & 3, so the level of powerassist and braking force remains constant. Thevacuum brake valve always seeks balancingposition whenever the brake pedal force isconstant.

43

BRAKES

Fig. 22

5.4 Beyond Vacuum limit (Fig. 47):As the pedal force becomes greater and thepressure in chambers 2 & 4 attains fullatmospheric level, the pressure differenceexer ted on the diaphragms reaches themaximum and a force beyond it will no longerwork on the diaphragm. So any further loadingthe output rod is directly transmitted to the mastercylinder without vacuum assistance.

44

BRAKES

5.5 Brakes on without vacuum (Fig. 48):In this condition, all chambers are in atmosphericpressure. When the pedal is depressed, the pistonmoves forward hitting the rubber reaction disc.In this condition the vacuum brake valve has noboosting action and the output force on the pushrod is given as below

Output force = Input force on the operating rod– Mechanical loss inside booster

The mechanical loss inside booster is mainlydue to spring loads and friction due to seals incover and rear housing.

6. BALANCING ARRANGEMENT:The balancing action of vacuum brake valve isby means of rubber reaction disc arrangementFig. 43. The input force on the operating rodmoves the operating rod assembly, which furtherexerts force on the rubber reaction disc. Therubber reaction disc acts as a compressed fluidtransmitting the force from the operating rod via.

Fig. 23

the piston to the push rod. The reaction forcefrom the master cylinder compresses the rubberdisc, which further transmits this force to thevalve body. The valve body balances this reactionforce by moving backwards, closing the air valve.The boost ratio is given by the ratio of the reactingareas on the push rod and the piston i.e

Boost ratio= Area of inner diameter of reaction area of push

rod / Area of Piston= D2/d2

Where D = Inner diameter of reaction area inpush rod

d = outer diameter of piston

By changing the diameter of piston and thecorresponding diameter of valve body, variousconfigurations of boost ratios can be obtained.

45

BRAKES

SERVICE CHECK

A. INSPECTION (As per recommended serviceschedule)

Check the tightness of the mounting nuts (torque20 Nm)

B. OPERATING TESTS

● Check for free movement of the push rod withoutbinding while applying/releasing brakes.

● Check for vacuum leak in brakes applied /released position by observing the vacuumgauge and ensure that the pipe lines and thejoints are free from leakage.

REMOVAL

1. Place wheel chokes in front and behind thewheels to prevent movement of the vehicle.

2. Remove the brake pedal return spring

3. Remove the fork pin of vacuum brake valve

4. Disconnect the hydraulic lines

5. Remove the master cylinder

6. Disconnect vacuum line connected to NonReturn Valve.

7. Loosen the mounting buts of vacuum brakevalve and remove the unit

DISASSEMBLY

1. Clean the exterior of the unit.

2. Loosen Nut (A/F 17) on Fork and remove Fork,Gaiter, Retainer and Filters.

3. Loosen Nuts (A/F 13) on Spacer & Removespacer and sealing ring.

4. Remove the Non return valve and Grommet.

5. Mark the position of the front & rear housing toensure proper orientation of master cylindermounting bolts in front housing with respect tothe rear housing-mounting bolts.

6. Place and position the unit in the dismantling /assembly fixture while fixture is clamped on abench vice.

7. Place and position the swivel block on the fronthousing.

8. Tighten the fixture handle to rest on the swivelblock. Avoid over tightening.

9. Rotate the rods and match the notches &dimples in line. Do not over rotate otherwise theassembly will get locked again. If loosening isdifficult, loosen the handle slightly and then rotatethe rods.

10. After the front housing gets unlocked loosen thefixture handle slowly until the front housing getsseparated fully.

11. Remove the Spring, Push rod, Spring seat andRubber reaction disc.

12. Remove the Key retainer.

13. Press the Operating rod and remove Key.

14. Remove the operating rod assembly from thevalve body by pulling it out at the fork end.

15. Separate cover and rear housing assembly.

16. Lift the Diaphragm on rear housing from thegroove.

17. Remove the Retainer, Spacer and Seal from Rearhousing.


1. Wash and clean all metal parts and blow dry withcompressed air.

2. Inspect all the parts for excessive wear anddeterioration.

3. Check Valve body bore and outer diameter forany score mark / crack / damage.

4. Check for any excessive wear in rubber reactiondisc.

5. Check for any damage in valve rubber cup inoperating rod assembly.

6. Check for any damage or holes or cut marks onDiaphragm.

REASSEMBLY

1. Use recommended repair kit and diaphragm toreplace old parts

2. Lubricate all moving parts (except diaphragm)with Silicone grease. This grease is suppliedalong with repair kit.

3. Press in the Seal, Spacer and Retainer in therear housing using a soft mandrel and ensurethat the Seal seats properly on the rear housing.

46

BRAKES

Use always a wooden mallet to tap Seal into theRear housing.

4. Apply grease on the Seal.

5. Push Operating rod assembly in the Valve bodyand assemble Key. Place Key retainer over Keyand press it.

6. Place and position the Diaphragm, Diaphragmdisc and Valve body assembly on the Rearhousing.

7. Place Diaphragm over Rear housing groove.

8. Place the Rear housing assembly with valvebody and operating rod assembly with Key onlocking fixture.

9. Place Rubber reaction disc, Push rod, Springseat and Spring.

10. Place and Front housing on the Spring and matchits notches with Rear housing notches.

11. Tighten the fixture handle simultaneously aligningthe notches of Front housing and Rear housingnotches in line. Continue tightening to allow theFront housing notch groove matches with rearhousing.

12. Rotate the rods uniformly without jerk to avoidtwisting of Diaphragm and lock the housings andmatch the marking.

13. Avoid grease / Oil contact with diaphragm duringassembly.

14. Loosen the handle and remove the unit from thefixture.

15. Assemble the Grommet and Non return valve inFront housing.

16. Assembly the Filters, Retainer and Gaiter.Ensure Gaiter is located properly on Rear housinggroove.

17. Assemble Nut on Operating rod assembly andassemble Fork on Operating rod assembly.Ensure that booster input rod standout dim is111 + 0.5 mm Fig. 53

18. Place Sealing ring , Spacer on Front housing andtighten Nuts.

19. Mount the unit on the vehicle and connect brakepedal return spring. Adjust pedal position and freeplay. Install the eccentric pin (smear pin withmolycoat grease)

20. Connect the vacuum pump line with the Nonreturn valve of vacuum brake valve.

21. Mount the Master cylinder on the vacuum brakevalve and connect the hydraulic lines.

TEST PROCEDURE

1. Bleed the hydraulic lines. Ref. brake bleedingprocedure.

2. Apply / release the brake without vacuumassistance and check for free return if brakepedal.

3. Depress the brake pedal fully before starting theengine (i.e. without vacuum in the system). Startthe engine. As vacuum builds up in the system,the brake pedal becomes light indicating properfunction of the brake valve and the brake system.

4. Check for vacuum leak in brakes on/off positionsby observing the vacuum gauge.

5. Apply / Release the brake with vacuum andcheck for free return of brake pedal.

NOTE :

Foam between firewall & vaccum booster is differentbetween normal 10” booster & ZDS booster.

Thickness of foam is more in case of ZDS booster.

Please ensure to use foam with correct thicknessduring fitment.

ZDS booster & TMC are matched by manufacturer forimproved performance.

However, this matching is not possible in field. Vaccumbooster & TMC can be changed independently in field.

47

BRAKES

CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF VACUUM BOOSTERCOMMON FOR NORMAL & ZDS BOOSTER

Engine Off : Depress and release brake pedal several times to remove vacuum from the system.

Depress pedal and hold with light pressure (7-12 kg) and start engine.

If Vacuum Booster is operative, pedal will fall slightly and then hold. Less pressure will be needed to holdpedal down, than with the engine in 'off'' condition.

If Vacuum Booster is not operative disconnect thevacuum hose from the Vacuum Booster non-re-turn valve. Then with engine running, check thevacuum supply with a vacuum gauge. Thereshould be atleast 20” of vacuum.

If Vacuum Booster is operative, do the vacuumleak test as given.

If vacuum supply is below 20" replace or repairthe vacuum hose and vacuum fittings.If the vacuum supply is 20" or more the VacuumBooster is defective and should be replaced withnew Vacuum Booster Assy.

With new hose fitting repeat the basic test.

48

BRAKES

VACUUM LEAK TESTCOMMON FOR NORMAL & ZDS BOOSTER

Run the engine to medium speed. Release the accelerator and turn the engine off. This builds up vacuum.

Wait 90 seconds and apply the brakes. Two or more applications should be Vacuum Booster assisted.

If the applications are Vacuum Booster as-sisted, there is no vacuum leak.

If the applications are not Vacuum Boosterassisted disconnect the vacuum hose from thenon-return valve. Then attach a short length ofhose to the valve.

Blow air through the hose. The valve is defective if air passes through.

If the non-return valve is defective install a newnon-return valve and repeat the vacuum leaktest.

If the non return valve is OK, the VacuumBooster is leaking. Replace the VacuumBooster with a new kit.

Check the performanceby applying / releasingthe brakes. Pedal shouldgo down easily whenengine is running and thepedal should returnswiftly on releasing thebrakes.Refer Fig 24

Preventive Maintenance (applicable for ZDS booster)

Every 10,000 km Every 20,000 km Every 40,000 km Every 80,000 km

Lubricate linkages &check for slackness atfork.Maximum allowedslackness-0.5mm.Refer Fig 24

Check the gaiter forproper fitment /existence of damage &replace if necessaryRefer Fig 25

Change filters & gaiterRefer Fig 25

Overhaul the assemblyusing recommendedrepair kit & diaphragma.Replace valve body &rubber reaction disc ifnecessary.

49

BR

AK

ESFig (a) Pin

Fork

Pedal

Fig 24

50 BR

AK

ES

Fig 25

51

BRAKES

CONSOLE MOUNTEDPARKING BRAKE (Fig. 26)

Parking brake is cable operated acting on therear wheels.

It is operated by a handle situated in the cabon console. (Fig. 26)

When the handle is pulled up, parking brake leverinside rear drum brakes is also pulled throughthe cable system.

This action expands rear brake shoes againstdrum, thus applying rear brakes.

OPERATION (Fig. 26 & 27)

Parking brake handle inside cab is to be pulledup to apply parking brake on rear wheels. Torelease parking brake, handle is to be lifted slightlythen keeping the release button pressed, handleis to be pushed down fully.

When button is pushed as above, pawl rod alsoget pushed, disengaging pawl from ratchet, thusreleasing parking brake.

Parking brake handle1. Parking brake released2. Parking brake applied.

Fig. 26

Fig. 27

1. COIL SPRING

2. SLEEVE

3. PAWL ROD

4. LEVER

5. PAWL

6. RATCHET

7. CASTLE NUT

8. SPLIT PIN

NOTE :LATERAL PLAY AT FULCRUM TO BE MINIMUM POSSIBLE(0.125 MM MAX.)TO ADJUST THIS PALY, TIGHTEN THE CASTLE NUT FULLY, LOOSEN THE NUT ONLY TILL THE HANDLE IS FREE TO MOVE,ENGAGE THE SPLIT PIN AT THE NEAREST HOLE ON THE BOLT AND BEND THE SPLIT PIN.

8 7

6542

1

3

A A

SECTION - A-A

52

BRAKES

DISASSEMBLY (Fig. 27)

1. Ensure that parking brake is in releasedcondition.

2. Unscrew and loosen parking brake adjustinglock nut and spherical nut at rear end offront cable.

3. Take out front ends of rear cables from linkby moving out cable end with button fromrecess provided in link.

4. Remove clips holding front ends of rearcables and rear end of front cable on thebrackets pull out the cables and remove thecables from mounting brackets.

5. Disconnect electric connection from parkingbrake switch.

6. Unscrew the mounting screws of ratchet ofparking brake unit inside cab.

7. Take out the front end of front cable fromparking brake lever after removing split pin,spacer and clevis pin. Remove parking brakelever with ratchet.

8. Remove holder from front end sleeve of frontcable. Remove front cable.

9. Only if necessary, dismantle the pawl, pawlrod and lever from ratchet by removing splitpin castle nut and bolt at, fulcrum. Removesplit pin, shim and clevis pin holding pawlwith lever, unscrew lock nut of knob on pawlrod, remove knob, lock nut, spring and sleeve.Remove pawl rod with pawl, push out dowelsleeve with suitable punch and remove pawl.

INSPECTION

1. Check front and rear cables for any damage.Replace the cable as an assembly if founddamaged.

2. Check ratchet, pawl, for wear / damage andreplace the defective parts.

3. Check other parts for damage and replacedefective.

ASSEMBLY

Assemble all par ts in reverse order ofdisassembly.

NOTE :

For adjusting parking brake switch, keeplever in the lowermost position and moveswitch mounting bracket upwards, to touchthe bottom of the lever. Then tighten thebracket mounting screws.

53

BRAKES

ADJUSTMENT OF PARKING BRAKEEnsure that all four rear brake shoes have beenproperly adjusted.

1. Put chocks on front wheels.

2. Jack up rear axle.

3. Loosen lock nut. Pull parking brake lever uptonotches.

4. Tighten spherical nut till rear wheels startjamming and cannot be rotated.

5. Release parking brake and ensure that wheelsare rotating freely. Hold spherical nut in thisposition and tighten lock nut.

6. Lower down rear axle.

7. Remove chock from front wheels.

INSPECTION OF PARKING BRAKE :

Pull parking brake lever at its centre by 20 kgforce, with this force the travel should not exceed5th notch position.

Check both wheels are locked at this condition andrelease lever (i.e. take it to ‘0’ notch) and check forfree rolling of wheels.

Both rear wheels should be free and there shouldnot be rear brake dragging.

For counting the notches easily, listen to the clicksound from ratchet while pulling parking brake leverwithout pressing button. A click sound pertaining toeach notch movement.

BRAKE PEDAL HEIGHT ADJUSTMENTIN LINE WITH CLUTCH PEDAL (Fig. 29)

Push rod of vacuum booster serves as brakepedal stopper when pedal is fully released. Brakepedal height adjustment should be performed asbelow :

1. Before assembling vacuum booster on firewallensure that the dimension 116.5 mm (Pushrod fork hole centre to booster mounting face)is properly maintained.

2. Assemble booster unit with foam packing onfirewall.

3. Install brake pedal with return spring on to thebracket. Connect brake pedal & push rod witheccentric pin.

4. Turn eccentric pin to get pedal height so thatboth clutch and brake pedals are at samelevel and tighten nut.

ENSURE THAT ON RELEASING THE PARKINGBRAKE BOTH REAR WHEELS ARE FREE.

Fig. 28 - Parking brake linkage adjustment1. Lock Nut 2. Spherical Nut

Fig. 29 - Brake pedal height adjustment

Eccentric pin

Section - AA

A

A

Vacuumbooster

Return spring

Brakepedal

5. If pedal does not return to its original positionmount return spring on distant hole.

CAUTION :

After rear brake drum is machined to repairsize of 283.5 mm dia parking brake willbecome ineffective, when usable stock ofbrake lining thickness reduces to 0.7 mm andbelow. Hence change brake linings with newone as soon as usable stock of liningthickness reduces to 0.7 mm.

54

BRAKES

CHART FOR L.C.R.V. GAP FOR 207 FAMILY

Sr. No. Version ●●●●● Gap to be maintained

01. Telcoline Pickup (4x2) 1.00 mm

02. Telcoline Pickup (4x4) 1.00 mm

03. Telcoline Crewcab (4x2) 1.00 to 1.2 mm

04. Telcoline Crewcab (4x4) 1.00 to 1.2 mm

LOAD CONSCIOUS PRESSURE REDUCING VALVE

Fig. 30

●

●

LEVER

LOCK NUT

ADJUSTINGNUT

CE

NT

RE

LIN

E O

F

RE

AR

AX

LE

SENSING SPRING

LINK ‘C’

HOLE A

HOLE B

VEHICLE FRONT

For pre loading in unladen vehicleassemble link pin in hole B and maintaina gap as shown in the table at locationmarked ‘●’ and then assemble the link inthe top hole A.

DETAIL - X

DETAIL - X

55

BRAKES

LOAD CONSCIOUS PRESSUREREDUCING VALVE (LCRV)

An LCRV valve is required in the brake systemduring severe braking. That time, most of thevehicle weight is transferred to the front, and thefront brakes do most of the braking. The rearwheels are left with little traction and in thiscondition under high time pressure, they have atendency to skid.

The valve is installed in the line to the rear brakedrums. During heavy braking the valve limits thepressure to the wheels & this allows rear wheelsto keep turning instead of locking up andskidding.

REMOVAL OF LCRV

Unscrew and remove hex. nut holding LCRV linkagewith mounting bracket on rear axle.

Unscrew and remove hex. screws holding LCRVwith mounting, bracket on frame. Remove LCRVassembly.

INSTALLATION OF LCRV

Position LCRV on mounting bracket at frame. Fithex. screws, and hex. nuts. Tighten screws to 2.1- 2.5 mkg. torque.

Fit link end on mounting bracket at rear axle withspring washer and hex. nut (M8 x 1.25). Tightenhex. nut to torque of 1.1 to 1.4 mkg.

ADJUSTMENT - VALVE SETTING METHOD

With link ’C’ in hole ‘B’ and vehicle in unladencondition, set the gap (●) between valve pistonstem and adjusting screw (as shown in the tablepage no. 54) with help of adjusting screw andlock nut. Tighten lock nut of adjusting screw. Thenengage the link ‘C’ in hole ‘A’ i.e. upper hole ofthe bracket.

NOTE :

Change the valve assembly and sensingspring together.

Fig. 31 - Construction of LCRV

56

BRAKES

TROUBLESHOOTING HINTS FOR THE BRAKE SYSTEM

A. SERVICE BRAKE

Sr. No. Trouble Cause Remedy

1. Brake pedal is soft and spongy. a. Air in brake system. a. Bleed brake system.

b. Brake fluid too hot (after long b. Give brake system time todown gradient travel of long cool and if necessary,time operation of brake). bleed.

c. One of both primary seals c. Replace primary seals.in tandem master cylinderdamaged.

d. Brake shoes worn out. d. Replace shoes.e. Soft or weak hose. e. Check and replace.

2. Brakes heat up when vehicle is a. Compensation port in tandem a. Dis-assemble tandemtravelling or fail to release. master cylinder clogged. master cylinder and clean.

b. Rubber parts swollen because b. Drain brake system andof usage of non-recommended dismantle the whole brakefluids. system. Replace all rubber

parts including the brakehoses. Fill brake systemwith one of the approvedbrake fluids.

c. Brake drum shoe clearance is c. Adjust.more.

d. Brake shoe return spring d. Replaceweak/broken.

e. Brake drum out of true of e. Rectify.scored

f. Anchor plate/caliper mounting f. Tighten bolts.loose.

g. Slack hub bearing. g. Rectify.

h. Vacuum booster piston seized. h. Rectify/replace.

i. Weak/broken pedal return i. Replace spring lubricatespring. Pedal linkage binding. pivot and linkage.

3. Unsatisfactory braking action a. Brake shoes oily or greasy. a. Rectify the cause ofdespite hard pedal pressure leakage and clean brake(normal pedal travel) drum/disc. Replace brake

shoes/pads.

b. Brake shoe/pads charred. b. Replace the parts.

c. Brake shoes/pads worn. c. Replace.

57

BRAKES


d. Vacuum booster defective d. Rectify/Replace.

e. Brake shoe/drum distorted. e. Check and rectify.

4. Unsatisfactory braking action a. Vacuum hose or connections a. Eliminate leaks.despite hard pedal pressure leaky.(short pedal travel)

b. Damaged vacuum seal in b. Replace vacuum seals.tandem master cylinder

c. Damaged O-ring between c. Replace O-ring.tandem master cylinder andvacuum booster.

d. Damaged seal on vacuum d. Replace vacuum booster.booster piston.

e. Tear in diaphragm. e. Replace vacuum booster.

f. Check valve sticking. f. Replace vacuum linetogether with check valve.

g. Defective vacuum pump. g. Repair vacuum pump.

5. Unsatisfactory braking action a. Drum to shoe clearance a. Adjust brakes.despite hard pedal pressure excessive.(long pedal travel)

b. Incorrect brake fluid. b. Flush the system and usespecified brake fluid.

c. Cracked drums. c. Replace brake drum.

d. Excessive wear in brake d. Inspect and rectify linkages.pedal linkage.

e. Wheel bearing play excessive. e. Adjust.

f. Mounting of brake part f. Rectify and tighten.loose/defective.

g. One brake circuit inoperative g. Eliminate leaks.through leaks.

6. Brakes dragging on one side. a. Brake shoes/pads oily or a. Check seals of wheel hub,greasy. replace brake pads/shoes.

b. Brake shoes/pads of one b. Replace brake shoes/pads.side excessively worn.

58

BRAKES


c. Difference in friction valve of c. Replace brake shoes/pads.brake shoes/pads.

d. Out of round drums. d. Correct by grinding/turning.

e. Bad tyres. e. Replace worn tyres.

f. Brake anchor plate/caliper f. Tighten firmly.mounting loose.

g. Corrosion traces on cylinder g. Check and rectify.bores.

7. Brakes squeaking or Judder. a. Brake drum out of round. a. Check and rectify.

b. Brake drum/disc out of true. b. Check and rectify.

c. Brake linkages having high c. Check and rectify.friction

d. Brake liners not chamfered. d. Check and rectify.

e. Excessive air gap between e. Check and rectify.liners and shoe.

f. Loose lining rivets. f. Check and rectify.

g. Anchor plate/caliper brake g. Tighten.mounting loose.

h. Lining/pad worn out h. Check and rectify.excessively.

i. Wheel bearing play not i. Adjustin order.

8. Rattling brakes. a. Unsatisfactory wear pattern a. Run in brake shoes.of brake shoes.

b. Uneven action of shock b. Check shock absorbers.absorbers.

9. Fluid reservoir needs frequent a. Leak in hydraulic system. a. Check all liners, hoses andtopping up. unions for leaks.

b. Brake fluid escaping from b. Replace vacuum seals inleak port of tandem master tandem master cylinder.cylinder. If necessary, remove brake

fluid from vacuum booster.

1

POWER STEERING

ZF Integral Hydraulic Ball &Nut Power SteeringGear - Short Version

3

POWER STEERING

These instructions are intended to assist in thenecessary maintenance and repair work carried outon the ZF hydraulic ball and nut power steering gears.

We would especially like to draw your attention to thefact, that steering systems must only be repaired inworkshops, where the following are available :

1. Trained personnel

2. Authorized equipment, among others, testbench, crack testing unit and special tools

INTRODUCTION

5

POWER STEERING

CONTENTS


I. Steering wheel and column mounting - Exploded view 6

II. Removal of Steering Column 8

III. Steering gear box exploded view 9

IV. Design of steering gear box 11

V. Oil filling and air bleeding 15

VI. Special Tools 17

VII. Removal of steering gear box from the vehicle 17

VIII. Dismantling of steering gear box 18

IX. Checking steering gear box parts 20

X. Tightening torque 20

XI. Assembly of steering gear box & functional testing 21

XII. Vane pump 26

XIII. Sectional view of vane pump 27

XIV. Power steering oil tank 28

XV. Faults and remedies 29

6

PO

WE

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Fig. 1

I. TELCOLINE (4X2/4X4, LHD/RHD, 28/31 WHEELBASE) - STEERING WHEEL AND COLUMN MOUNTING

7

POWER STEERING

LIST OF PARTSS.NO DESCRIPTION1. ASSY STEERING WHEEL (380 DIA BLACK)2. SPRING WASHER B143. HEX THIN NUT M14 X 1.54. HORN PAD (COL-BLACK, 380 DIA)5. HEX. SCREW M6 X 206. SPRING WASHER B67. BOSS8. ASSY. STEERING COLUMN (FOR STEERING LOCK)9. ASSY. STEERING SPINDLE TOP10. DEEP GROOVE BALL BEARING (M/S. SKF 6004 2Z)11. INTERNAL CIRCLIP 42X1.75 N12. SPRING SEAT13. COMPRESSION SPRING (STEERING COLUMN)14. SPRING SEATING CUP15. ASSY. UNIVERSAL JOINT16. BOLT17. NYLOC NUT M818. TENSION SPRING19. SPLIT PIN 1.6X1220. BRIGHT WASHER 6.421. ASSY. STAY BRACKET22. WASHER A8.4 IS:5370 ST.23. SPRING WASHER B8 IS306324. HEX. SCREW M8 X 1625. ASSY. BRACKET (STG. COLUMN MTG.)26. ASSY. RATCHET27. TAB WASHER 8.428. FITTING SCREW29. WASHER30. BOLT WITH NYLON INSERT31. ASSY. PAWL WITH GUIDE PIN32. DISC SPRING B1633. BRIGHT WASHER 8.434. WASHER (1.25 MM THICK)35. CIRCLIP E 7.0 X 0.936. BUSH (CAM PIVOT)37. ASSY. SLEEVE38. STEERING SPINDLE (MIDDLE)39. ASSY. SLEEVE41. RUBBER BELLOW (SLEEVE/TOP)42. STEERING SPINDLE BOTTOM43. SHIM (1 THICK)

SHIM (0.5 THICK)44. SPHERICAL SUPPORT (STEERING SPINDLE)45. BRACKET (STG. SPINDLE SPH. SUPPORT)46. HEX. SCREW M6X16 IS:1364

8

POWER STEERING

II. Removal of Steering Column From vehicle :

Caution

This is tiltable steering column. Proper precaution mustbe taken to disassemble the unit.

1. Dismantle the universal joint connection on thesteering gear box end & near the fire-wall & takeout the steering spindle bottom.

2. Remove the steering wheel.

a. Remove the side covers on the steeringwheel.

b. Dismantle the two screws on the side ofsteering wheel.

c. Take out the top cover of steering wheel afterdismantling the horn connections.

d. Dismantle the steering wheel by proper puller.

e. Dismantle the bottom cover of steeringcolumn.

3. Dismantle the nacelle top & bottom.

4. Dismantle the combination switch.

5. Removal of Steering column unit.

a. Dismantle the screw of steering ball jointbracket assy. from fire wall.

b. Dismantle the screws on the dash board crossmember & assy stay bracket.

c. Take out the steering column from the thevehicle.

Installation of Steering column on the vehicle :

1. Check the following for the condition of steeringcolumn.

a. Free rotation of steering spindle.

b. Steering spindle bottom for grease.

2. Assemble the steering column on the vehicle, atfirewall & on the column mounting bracket.

3. Assemble the combination switch on the steeringcolumn.

4. Assemble the nacelle bottom & top on the steeringcolumn.

5. Assemble the steering spindle bottom, on thesteering gear box end & on the fir wall end.

6. Assemble the steering wheel, on the steeringcolumn, in wheels straight ahead condition.

Fig. 2

��

Nacelle BottomCover

9

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Fig. 3

III. EXPLODED VIEW OF STEERING GEAR BOX

10

POWER STEERING

S.NO QTY DESCRIPTION / EXPLODED VIEW NO. REMARK

1 1 HOUSING ASSY RHD

1,5,5,1,6,6,1,6,2,7,10,11,5,2 LHD

2 2 SUPPORT RING (6)

3 2 GASKET (6.1)

4 1 NEEDLE ROLLER BRG (5.2)

5 1 SEALING RING (6.2)

6 1 SNAP RING (7)

7 1 PROTECTIVE CAP (XXX) M16X1.5

8 1 PROTECTIVE CAP (XXX) M14X1.5

9 1 SECTOR SHAFT ASSLY 30,31,32,33 RHD/LHD

10 1 HEX NUT (35)

11 1 TAB WASHER (36)

12 1 SEALING NUT (50)

13 1 PISTON ASSLY (90) RHD

70,94,95,96,97,98,99,100,101,102,103, 107,108,110,112,113,115, LHD

116,117,117.1, 118,118,1,120,123,124,128,129,130, 131,143,144,145

14 1 HOUSING COVER ASSLY RHD

(40,41,43,44,48,49,51,52) LHD

15 2 O’ RING (42,121)

16 2 O’ RING (43,120)

17 4 HEX SCREW (46)

18 4 WASHER (47)

19 1 SUPPORT RING (51)

20 1 GASKET (52)

21 1 SHAFT SEAL (129)

22 1 V’ RING (130)

23 1 PROTECTIVE CAP (70)

24 1 SEALING KIT COMPL. RHD/LHD

6,6.1,6.2,42,43,51,52,70,94,94.1,95,97, 98,98.1,102,103,120,121,129,1.1

25 1 DUST SEAL (1.1)

26 4 HEX SCREW (132)

27 1 SMALL COMPONENTS (35,36,46,47,48,49,50,131,132)

28 1 STEERING GEAR ASSLY RHD

29 1 STEERING GEAR ASSLY LHD

LIST OF PARTS FOR STEERING GEAR BOX :M033 955 802 - 2659 4620 0168 - Telcoline LHD M033 955 805 - 2659 4620 0169 - Telcoline RHD

Note: All the components are common unless mentioned in the Remarks column.

11

POWER STEERING

IV. Design

1.1 Worm :

Both radial and axial roller bearings aremounted in intermediate cover (122*) and cover(128) or only in cover (128) depending on theversion. Worm Shaft with grooved channel forball circulation is mounted in this cover.

1.2 Piston :

Valve bush which accommodates the valvespool is pressed into cross bore hole.Underside of the piston is machined as a gearrack, which engages in the toothed segment ofsector shaft. Steering nut and finger passesinto longitudinal bore hole of the piston, thusestablishing the connection with valve spoolthrough worm.

Depending on the version, valve is centered bymeans of centering springs, leaf springs, orbending bar.

1.3 Steering nut :

Longitudinal bore hole for worm engagementwith grooves for ball circulation are provided.Groove on the external diameter is milled andground for accepting the finger, which engagesin cross bore hole of valve spool. Thisestablishes the connection to worm by meansof ball chain. In, steering nut - worm, dependson the selection of the corresponding type ofball.

Steering nut is mounted in piston, play-free,between two roller bearings. Adjustment iscarried out by turning threaded ring (118) whichis secured on the open side of the piston.

1.4 Housing :

Housing has integrated passages for pressureand return lines and, a built-in pressure limitingvalve. Oil passages which are required withinthe steering system are arranged as bore holesin housing, housing cover / plate or in piston.No external connecting lines are required due tothis design. Housing has mounting holes andmachined surfaces for securing steering gearbox on mounting bracket of the vehicle.

1.5 Sector shaft :

Sector gearing is cut with a flat angle to theshaft axis in order to facilitate, serviceadjustment in axial direction. Center tooth isshaped more convex, so that re-adjustment canbe carried out in straight ahead position (SAP),since this is the area where greatest amount ofwear occurs, without the following gear teeth,both left and right, becoming jammed.

Forces in axial direction are taken up bymeans of an adjustment screw (31); screw isheld into the bore hole of sector shaft, play-freeand passes through threading in housing cover.Adjustment in axial direction is carried out byutilizing this thread pitch and locking is doneby means of a lock nut.

1.6 Housing cover :

It houses the adjustment screw for supportingsector shaft & two built-in adjustable valves(55) for limiting the pressure at wheel lock.Valves are pushed open by the cam of sectorshaft in predetermined positionat left or rightlock. This enables pressurized oil to flow fromthe corresponding side of cylinder chamber to

12

POWER STEERING

a reduced required pressure of approximately30 to 35 bar. The device is described as“hydraulic steering limiters.”

2. Function :

In order to obtain hydraulic support duringsteering of vehicle, spool valve must be movedout of neutral position.

Spool valve is held in neutral position bymeans of a centering spring or bending roddepending on the version. Steering forces musttherefore be applied in order to overcome thisinitial setting.

Piston which is positively connected withsector shaft and steering wheel, offersresistance to rotation. Steering nut is thereforerotated by worm and ball chain during steeringprocess, thus overcoming initial setting ofcentre spring or bending bar. Pressurized oilflowing into the gearbox housing from enginedriven pump is then routed into the chambersfrom which the steering procedure ishydraulically supported.

Oil flows in from housing side into alongitudinal groove of piston and beneath thevalve. It also flows into a longitudinal groove ofthe same size on opposite side in order toassist pressure compensation and thenreaches, by means of cross bore holes, at thefront surfaces of valve pistons which areseparated from chambers by means of seals.In the neutral position of valve, oil flows tocentre of the valve piston after first flowingthrough forward and return edges, and fromthere oil flows up through the correspondingholes into an opening of the piston. Oil is thendrained for return motion. By operating thevalve, side of the piston which is underpressure is separated from return and oppositeside of the piston which is connected to returnflow. Spool valve is equipped with two feed-back pistons which have the task of makingmovement of the valve, from neutral positionmore difficult, depending on oil pressure.Activating force on steering wheel increasesproportional to the forces which are applied towheels.

Steering gear boxs which only require aproportional increase of the steering force onlyup to a predetermined oil pressure, areequipped with Hydraulic reaction components(feedback piston). Valve which is into thefeedback piston ensures that after reachingcut-off pressure, force on steering wheel onlyincrease insignificantly.

Function of feedback pistons :

(Hydraulic Reaction)

They are floating pistons mounted in the borehole of valve spool. They are, however, heldaxially and secured by connecting them withretaining plates. Outer front areas of twopistons are continually under pressure whileonly one of the internal front surfaces is underpressure in working position of valve. Sameapplies for the front surface in bore holes ofvalve spool. In this way, no force occurs whichtries to push valve spool into neutral position.This proper ty is described as “hydraulicreaction”.

13

POWER STEERING

9 Threaded ring

10 Angular ball bearing

11 Cover

12 Pressure limiting valve

13 Vane pump with flow limiting valve

14 Oil Reservoir

15 Feedback piston (Hydraulic Reaction)

16 Valve piston

17 Driver

1 Housing

2 Piston

3 Worm

4 Bending Bar

5 Sector shaft

6 Balls

7 Steering nut

8 Threaded ring

Fig. 4 SECTION VIEW of a balland power steering gear withvane pump connected to it,steering valve in neutral position.Centering of the steering valveby bending bar.

OIL FLOW : after flowing throughsupply and return flow controledges to the middle of the valvespool and through bores to theright and left cylinder Chamber.

It goes through respective boresto a recess on the piston top,from here back to the oil tank.

Fig. 4 Steering valve in neutral position

14

POWER STEERING

Fig. 5 & 6 Steering valve in operating position

Fig.5 VALVE IN OPERATINGPOSITION, steering wheelturned clockwise, valve spoolmoved to the right, pressure oilgets into the cylinder chamber,left cylinder chamber connectedto return flow.

Fig.6 VALVE IN OPERATINGPOSITION, steering wheelturned anticlockwise, valvespool moved to the left,pressure oil gets into thecylinder chamber, r ightcylinder chamber connected toreturn flow.

15

POWER STEERING

In this way air remaining in the cylinder isreduced to a minimum. This is an insignificantamount which will be bled automatically duringoperation.

Steering system should be filled through theopening on reservoir. For the first filling andfor oil changes, it is recommended to removethe cover of container and fill with oil up tothe edge of container.

Engine should then cranked briefly a numberof times with starter, in order to fill entiresystem with oil. Since this causes oil level inthe container to fall rapidly, oil must becontinually topped up during this process.Under all circumstances, the pump must beprevented from taking in air.

Ensure that oil level does not fall below uppermarking on dipstick when engine is switchedoff.

3.2 Bleeding :

Jackup steering axle. Start engine and run atidling speed.

Allow engine to run for some time at idlingspeed, thus allowing most of the air to escapefrom cylinder. Oil level must be observedduring this process. Oil must be topped upimmediately if the level still sinks.

When the above instructions have beenobserved, oil level in container must not risehigher than 1 to 2 cm when engine is switchedoff.

Note :

Steering gear 8043 / 8033 / MO33 are systemwith automatic bleeding and do not have ableeding screw. These steering systemsautomatically bleed remaining air in the systemafter the bleeding process has been carriedout as described above.

Switch off engine.

4. Checking oil level :

Oil level should be checked at operatingtemprature at specified intervals.

4.1 Oil check on stationary engine :

V. Oil Filling and Air Bleeding

Note :

There is a danger that dirt particles may entersteering oil circuit when filling steering systemwith hydraulic oil.

A high degree of cleanliness must beobserved for first filling and for all subsequenttopping up operations in order to prevent failuredue to foreign bodies in the system. For thisreason, thoroughly clean oil reservoir and thearea around it before removing oil reservoircover or dipstick so that dirt does not get intooil.

1. Type of oil :

AFT oil must be used in order to ensureperfect function of the steering gear box andpump. The oil also carries out the lubricationof steering gearbox and pump.

2. Oil quantity :

Total system capacity is 1.6 ltrs.

3. Oil filling and air bleeding

3.1 Oil filling

Note :

Special care must be taken during theprocedure given below, to ensure that oilreservoir is not allowed to run empty sincethis would cause air bubbles in the steeringsystem.

In addition to this, special care must also betaken during oil filling and air bleeding toensure that steering pump only turns at lowestpossible speed (idling).

If the inlet flow is too great, small air bubbleswould enter the pump and be split up intoextremely small air bubbles during its passagethrough the pump; this situation may lead tofoam formation thus greatly extending thebleeding process.

Due to various types of installationpossibilities of gear box bleeding process maytake longer time. In such a case, drop armshould be removed so that the entire pistonstroke from stop to stop can be utilized forbleeding process.

16

POWER STEERING

In order to establish that no air is sucked inwhen engine is started, it must first beestablished whether oil loss has occurred whenengine is stationery. Therefore, the containershould be filled approximately 1 to 2 cmabove the upper marking on dipstick.

4.2 Oil check on running engine :

Oil level falls slightly when engine is runningsince the oil requires a pressure of 2 to 4 barto flow through the steering gear box as aresult of the resistance to flow.

Oil should therefore once again be topped upso that oil level lies constantly at the uppermarking. Engine can then be switched offagain. If this level is exceeded, then this is asign that there is still air in the system.

5. Changing oil and Filter

Filter has to be replaced at specified intervals.

Oil & filter has to be changed when steeringgear box or pump are repaired or replaced. Oilpipes/hoses also have to be cleaned.

When soiled filter cartridge is removed, bottomopening of the filter must be closedimmediately while removing from the filter fromits support to prevent dirty oil in filter cartridgeflowing back into reservoir and entering oilcircuit.

6. Inspection Recommended :

Steeering system should be inspected ininstalled condition, corresponding to theintervals laid down in the following tabledepending on vehicle application.

Apart from installing a new filter this inspectionalso entails a functional test of the entire unitand repairs if needed.

It is not necessary to remove steering gearbox and pump from vehicle for the first andsecond inspection. Removal of steering gearbox or pump can be considered, if any defectis established.

In the case of the third inspection steeringgear box and pump should be dismantled tocheck wear, damage, cracks & otherparameters.

Note :

If oil loss is apparent, check for leaks andrepair if necessary. Repairs to steering gearbox and pump must only be carried out inauthorised service stations.

Long distance traveling Long and short distance Traveling on building sites

traveling and cross - country

I. Inspection 100 000 km 100 000 km 80,000 km

II. Inspection 200 000 km 175 000 km 1,50,000 km

III. Inspection 300 000 km 250 000 km 2,00,000 km

17

POWER STEERING

VI. SPECIAL TOOLS

Tool No. 1Servo Tester7418 798 530

Tool No. 2Tongue For Piston Assly.M02851

Tool No. 3Assembly vice for steering gearM02903

Tool No. 4Torque measuring device(without insert)7470 798 703

Tool No. 5Insert for torque measuring device8052 798 552 (1 x 54 notches)

Tool No. 6Entry bush for shaft seal7832 798 001 (1 x 54 notches)

VII. Removal of steering gear box from vehicle

1. Thoroughly clean the steering gear box and thearea around it paying particular attention to lineconnections.

2. Drain the oil, by opening drain plug (48) or oneof the pipe connections.

Turn steering wheel so that the piston isshifted upwards up to the stop. Then briefly(maximum 10 seconds) crank engine until oilis sucked out of pump and reservoir. Afterswitching of engine, turn steering wheelseveral times to the left and the right stops,so that oil remaining in cylinder chambers ispumped out.

3. Disconnect pressure and return lines fromsteering gear box.

4. Plug all openings, to prevent dirt entering thesystem.

5. Remove steering drop arm with a suitablepulling device. Under no circumstances mustdrop arm be removed by driving a wedgebetween the neck of housing and steering droparm or with hammer blows, since this maycause serious damages to gear box.

6. Valid for steering gear boxs with universaljoints :

a) Loosen universal joint or flexible couplingbetween steering gear and steering column.

b) Remove securing bolts on housing andwithdraw steering gear box.

18

POWER STEERING

VIII. Dismantling Steering Gear Box

A) Removal and dismantling of housing coverplate

1. Clamp steering gear box between the soft jawsof a vice.

2. Remove hexagonal bolts (46). Removehousing cover (40) by turning adjustmentscrew (31) in clockwise direction (Figure 7.)

Dismantling in ZF factory only or ZF dealers.

2.1 For steering version with needle bearing:

Withdraw needle sleeve (41) with acommercially available internal puller andwithdraw protective disk (44) with seal parts(51 and 52) from bore hole.

Dismantling in ZF Factory or at ZFAuthorised Centre only

2.2 For steering versions with roller bearing

Note :

Rollers of roller bearing (5 and 41) have beensorted into certain tolerance groups. Therefore,rollers removed from bearing external ring onthe cover side must not be interchanged withrollers removed from the housing side.

B) Removal of Sector Shaft

Withdraw sector shaft (30) in the centerposition of the gearing(tooth), upwards out ofthe housing (Figure 8). Further dismantling inZF factory or ZF authorized dealers only.Remove the circlip (33) from he sector shaftand withdraw the adjustment screw (31) withthe guide washer (32).

C) Removal of Piston

1. Remove the protective cap (70) from the wormend. Screw out the securing bolts (132) (Fig.9). A burr (ridge) may have formed on theside of the piston gearing depending on theservice duty of the steering gear box, and thiswill damage the piston running surface whenthe piston is removed from the housing. Thiscan be avoided if the unit is dismantledhorizontally overhead (gearing toothuppermost). (Fig. 10) shows dismantling in anunfavorable position,

Fig. 7

Fig. 8

Fig. 9

19

POWER STEERING

Fig. 10

Fig. 11

Fig. 12

1.2 For steering version with threaded ring.

Withdraw the piston with worm and cover (128)from the housing.

2. Remove the seal parts(94,94.1,95,97,98,102,103,120 and 121)

D) Dismantling housing,

Removal and fitment of seals 6 & 6.1 isallowed. Further dismantling of rollers andbearing race is permissible in ZF factoryonly.

E) Dismantling of piston

(Permissible in ZF factory only)

1. Removal of Spring Element

1.1 For steering version with centering spring

Loosen the slot nut (101) with special tool, andturn out of the piston with the threaded studwith slot nut.

2. Removal of Steering Nut and Valve Piston.

Permissible in ZF factory only:

2.1 Strike open the caulking at the grooves at thethreaded ring (118) and unscrew the threadedring with special tool.The ring is sealed withLoctite; it can only be removed by heating upto a temperature of approx. 1250C Heatingmust be carried out in a suitable oven. In thiscase, it is recommended to immediatelyloosen the two machine screw (99) and thenthe two countersunk screws (115) afterremoving the steering nuts (these are alsofitted with Loctite.)

2.2 Withdraw the worm with the steering nut (114)from the piston.

2.3 Screw out the two machine screws (99) andwithdraw the feedback (96) out of the valvepiston.

3. Dismantling steering nut :

Unscrew the two countersunk screws (115) onthe cover plate (116) (Figure 11). Remove thecoverplate; shake the ball circulation tube(114). Remove the steering nut, needle cage(143), axial disk (124), threaded ring (118),intermediate shaft (122) axial disk (124) andthe needle cage (144) from the worm.

20

POWER STEERING

X TIGHTENING TORQUE :SR.NO DESCRIPTION VALUES1 FRICTION MOVEMENT OUT-SIDE“SAP”,MEASURED 40-60 NCM

AT INPUT SHAFT OF STG. GEAR BOX2 FRICTION MOVEMENT AT “SAP”, MEASURED AT ADD 70-150 NCM

INPUT SHAFT OF STG. GEAR BOX HIGHER TO 1.3 HEX. BOLTS(132)/COVER(128) M10 = 62NM

M12X1.5 =115 NMM14X1.5 =190 NM

4 HEX. BOLTS(46)/COVER(40) M10 = 62NMM12X1.5 =115 NMM14X1.5 =190 NMM16X1.5 =285 NM

5 SEALING-NUT(50) 70 NM

4. Dismantling the spring element :

Permissible in ZF factory or ZF AuthorisedStation only:

3.1 For steering version with centering spring

Unscrew the countersunk screw (114.3) andpress the finger (114.2) out of the groove ofthe steering nut. Remove the two spring plates(114.6) and the centering spring (1144.5) fromthe finger.

F) Removal of worm from threaded ring incover.

Permissible in ZF Factory or ZF AuthorisedStation only:

1. Clamp the cover (128) in the vice with theworm thread pointing upwards. Knock open thecaulking of the two grooves of the threadedring with special tool. The threaded ring issealed with Loctite.

1.1 For steering version with angular ball bearing.

Remove the axial disk (124), axial needlecage(143), worm, ball holder (144) and bearingring (145) one after another. Remove the circlip(130) and the shaft seal ring(129).

IX Checking Steering Parts

Note : Thoroughly wash all parts in a cleaning fluid.Clean Loctite residue from the threads. The sealrings and other rubber parts must not be cleanedin trichloroethylene but with a suitable washingliquid, such as P 3 or Pril, which is completelysoluble in water.

Checking : Check the parts for wear, damage orother defects in order to establish whether theparts can be used again. Only new parts suitable

for the type of steering and corresponding to thespare parts list should be used, see type plate. eg.M033 955 804

Important : The test requires detailed specialistknowledge and conscientiousness. The fitter mustbe responsible for the decision as to whether theparts needed changing or not.

1. Housing and housing cover

1.1 Cylinder bore. Max. wear dimensions of thebore diameters for honing:

8033/M033 = 78.055 mm

8043 = 101.56 mm

1.2 Threads

2. Piston*

2.1 External diameter

2.2 Gearing (crack testing longitudinally andlaterally with a suitable testing procedure suchas ferro flux). Scrap all parts with cracks.Remove any burr (ridges) on the sides of thegearing. Permissible in ZF factory or ZFAuthorised Station only.

3. Sector shaft

1. Teeth (crack testing, longitudinally and laterally,with suitable testing procedure, e.g. ferro- flux.)Scrap all parts with cracks.

2. Running surfaces of the needle/roller sleevesand the shaft seal ring.

4. Needle/Roller bearing and Ball bearing

The relevant bearing should be changed in thecase of indentation or wear on the running surfacesof the steering parts.

21

POWER STEERING

XI Assembly of the Steering Gear Box andFunctional Testing

Before assembly, all traces of paint and damagesmust be removed from the face surfaces of thehousing and cover. In addition, all parts must bethoroughly cleaned, lightly oiled and all sealingparts must be renewed. The measuring andadjusting tools used must be regularly checked foraccuracy.

Permissible in ZF factory or ZF AuthorisedStation only.

Apply Loctite to the threaded rings (118 and 118.1),machine screws (99) and countersunk screws(115). This requires that the parts are dry, oil andgrease free. That the oil Loctite deposits areremoved and that the sprayed activator isventilated. Pretreating the contact surfaces withactivator T Accelerates the initial hardening time.The Loctite should be applied so that no excessloctite drips onto the parts after they have beenjoint together. Hardened Loctite drops may lead tofunctional disturbances. Loctite joints should onlybe separated after the Loctite has fully hardenedand then refitted together. The use of Loctite is notdealt with in any further detail in the repairinstructions, expect for the fact that care shouldbe taken to select the correct identification numberof the type of the Loctite to be used.

Hardening times for loctite identification No. 222and 270 at room temperature.

After 2 hrs It can be transported,Adjustment of the hydraulicmedium possible with air.

After6 to 8 hrs Completely hardened, adjustmentof the hydraulic medium possiblewith oil or final testing on thetesting rig.

A) Preassembly of housing

1. Clamp the housing in the Assembly Vice Tool-No 3.

1.1 For steering version with roller bearing

Note :The rollers of the roller bearings (5 and 41) havebeen sorted out in certain tolerance groups by themanufacturer. Therefore, the rollers removed fromthe bearing outer ring on the cover side must notbe interchanged with the rollers from the housingside.

Permissible in ZF factory only

1.1.1 Place the supporting disk (5.1) in the bearingneck bore hole

For roller bearings without roller cage.

Press the outer ring of the roller bearing (5), withthe roller, into the housing until it reaches the collarusing, and lock in position by making 6 notchesaround the circumference. (The rollers are fittedwith with grease and a polymide filler piece in theroller gap; this provides protection when the partsare stored and remains in the steering gearbox).Insert the sector shaft; this is important forinstalling the seal rings (6.1 and 6). Remove thesector shaft.1.1.1 Place one round seal ring (6.1) and one sealring (6) in each of the two radial grooves of thehousing neck. Special care must be taken toensure that the polyamide rings with the beveledsurface lie on the same inclined surface of thegroove.

B) Preassembling the segment shaft

Fit the adjustment screw (31), guide washer (32)and circlip (33) in the Sector Shaft with thepunched curve outwards. The adjustment screwshould be fitted play – free but must not jam.(Refer to technical data)

C) Preassembling the piston and adjusting thehydraulic reaction.

Permissible in ZF factory or ZF AutorisedStation only.

22

POWER STEERING

D) Fitting the piston

1. Fit seals (95) in the longitudinal grooves of thepiston and then fit the seals (94).(Fig. 12)

2. The pair of seals (97 and 98) are also fittedwith the inner seal (97) first and then the outerseal (98). Place the round seal ring (102) inthe recess of the piston and then fit the pistonring (103). Special care must be taken whenpassing the seal over the piston to ensure thatno damage is caused by the edges of thepiston. The small round seal rings (121) mustbe adhered to the recess of the of the cover(128) by means of grease. Lubricate thecylinder path well with oil.

Slide in the preassembled piston up to theshoulder with the Tool –2. In order that the sealparts are not damaged the piston should befitted in its final position, i.e. gearing(tooth)parallel to the housing sector Shaft bore.(Fig. No 13)

E) Fitting The End Cover

1 For steering version with threaded ring in thecover: screw in and tighten the hexagon bolts(132) with the washers (131).

Slide the entry bush over the serrated gearingof the steering spindle, press the shaft sealring (129) with the sleeve so deep that thecirclip (130) can just be fitted in its groove(sealing lip pointing towards the inside of thehousing. Fill the space between the sealing lipand the dust lip with hot bearing grease) fit thecirclip (130) (Fig. No.14)

Refer to the technical data for tightening torques.

F) Pre-assembly of the Cover.

1. Fit the round seal ring (52) and the seal ring(51) in the radial groove. Special care must betaken to ensure that chamfered area of thepolyamide ring lies in the same chamferedsurface of the groove.

2. Fit the supporting washer (44) in the bore holeof the housing cover. Press the roller bearingduly fitted with the rollers with grease and thepolyamide filler piece (41) upto the shoulderswith a drift and secure by stalking the collarat 6 points on the periphery.

Fig. 13

Fig. 14

Fig. 15

23

POWER STEERING

G) Fitting the Sector Shaft.

1. Bring the piston to the center position byturning the Input Shaft. This center point isfound by first determining the total number ofturns of the worm then turning back the pistonfrom one stop by half the total number ofturns.

1.2 Insert the segment shaft into the housing,taking care not to damage the sealing parts.

H) Fitting the housing cover

1 Fit the two round seal rings (42 and 43) in theaxial groove of the housing cover (40).

1.1 Fit the housing cover (Fig-15). Position thehousing cover by turning the adjusting screw(31) on the front surface of the housing in acounter – clockwise direction and screw on thesealing nut (50) temporarily.

Screw in and tighten the hexagon bolts (46)with washers (47).

Screw in the threaded plug (48) and tighten(refer to the technical data for the tighteningtorque).

I) Setting the pressure Point

1. Place the torque measuring unit Tool No.4 andinsert Tool no.5 on the worm.

2. Turn the steering from the one end position tothe other. Measure the frictional force outsidethe pressure point and determine the total turnof the steering wheel.

3. Then set the frictional force in the area of thepressure point (mid position; half of the totalturn of the steering wheel). The torquemeasuring device is turned both to the leftland right of the center position and theadjusting screw should be screwed out so faruntil an increase in the friction torque of 40-60Ncm compared to the value measured in point2 is set (Figure 16).

4. Tighten the sealing nut (50) (refer to thetechnical data of the tightening torque), whileholding the adjusting screw in a fixed position.Check the set torque once again. Fit theprotective cap (70).

Fig. 16

J) Checking the frictional torque of thecompletely assembled steering gear box

Place the torque measuring device Tool no.4and insert Tool no. 5 on the worm. Turn thesteering gear box form one end position to theother. Measure that frictional torque outside thepressure point in a horizontal position (refer tothe technical data.) piston (see Section D).

K) Functional Test :

Clamp the completely assembled steering gearbox on the steering test rig according to theinstructions given in section VII after Finalhardening time for loctite. Bleed the steeringgear box (see section II) and increase the oiltemperature to approximately 50oC.

The adjustment values given in section VII arevalid the for setting pressure point of thesteering system after completion of the repairson the workbench. There is no oil in thesteering gear box.

L) Testing the maximum pressure :

Block the steering gear box in the mid position(steering gear boxs without hydraulic steeringlimiting system can also be turned to the stop).Turn the steering wheel until the maximumpressure has built up on one side of thecylinder. For this purpose it is necessary toapply a force of 100-200N (10-20 kg) to theperiphery of the steering wheel so that themaximum path of the valve is utilized.

24

POWER STEERING

If the steering gear box is fitted with apressure limiting valve a maximum pressuremust be built up which corresponds to thespecifications given on the type plate(tolerance + 10%). If the steering gear box hasno pressure limiting valve then the pressurelimiting valve built into the testing rig must beset to the rated pressure which ispredetermined for the steering gear box (thiswould correspond to the rated pressure whichis given on the type plate of the pump).

The same measurements are now carried outin the opposite direction of the steering wheel.If the maximum pressure is not reached withinthe specified tolerance, the oil leakage in thesteering system is either too great or thepressure limiting valve, if applicable, isincorrectly adjusted. The latter can also be thereason for too high maximum pressure.

M) Checking for oil leaks :

The control valve must be fully activate inorder to be able to determine the leakage oilin the steering system. For this reason aminimum of approx. 200 N (20 kg) must beapplied to the steering wheel. The test iscarried out with the pump running and apressure is set on the steering testing rigwhich lies approximately 20 bar below themaximum pressure given on the type plate.

The maximum permissible leakage oil underthese conditions is:

1.8 LPM for type 8033-8037

2.0 LPM for type 8038-8043

The test can be carried out with blockedsteering drop arm or in the end position of thecylinder. Repeat the leakage oil check at apressure of 20 – 30 bar.

N) Checking the valve setting :

The pump is running and the oil circulatesthrough the hydraulic system of the steeringgear box. No counter force is set on thesteering shaft in the steering test rig. Thehydraulic steering is turned slowly to bothsides up to the stops in each case and thetorque measuring device is released severaltimes during this process. The steering mustnot move in any direction on its own. The

difference in the torques when steering to leftand right must not exceed 30% in respect ofthe low value up to a pressure of 3 barcompared with the flow pressure when thesteering drop arm is blocked

O) Checking control valve :

Close the control valve by turning the steeringwheel then build up the maximum pumppressure. The steering wheel should then beslowly released. The valve should then returnto the 0 position, i.e. the oil pressure must fallto the flow pressure.

P) Checking the seals :

No leaks should be visible on the hydraulicsteering gear box after running for 10 minutesin the neutral position of the steering valve.

Tightness at high pressure must bedetermined during the test in accordance withpoints 2 to 4 of this section. Place the dustseal (1.1) on the segment shaft up to theshoulder, applying HTR2 grease or equivalentbetween the dust seal and housing, and placethe protective cap (70) on the steering spindleend, applying HTR2 grease or equivalentbetween the protective cap and valve housing.

IX Fitting the steering gear box in the vehicle

Note :

In order to ensure perfect functioning of the ZFhydraulic ball & nut steering, special emphasismust be paid to cleanliness when fitting allrelevant units of the system and when layingoil lines. In order that faults can be avoideddue to foreign bodies or dirt in the oil steeringcircuit the cap plugs on the line connectionsof steering gear box, oil pump, workingcylinder, valves etc. should only be removedwhen connecting the lines. Connection linesand securing elements must be carefullycleaned and deburred.

1. Clean any paint or dirt from contact faces ofmounting brackets.

2. Insert steering gear in mounting bracket andtighten bolts to required torque.

3 Stresses which may occur during theassembly of the steering gear/bearing blockdue to the position of dash board or on the

25

POWER STEERING

circumstances when securing steering columntube and steering spindle.

Stresses can cause bending forces especiallyin steering spindle which, depending on sizeand frequency, may lead to fractures or impaireasy movement of steering gear.

To check whether the steering gear box has beeninstalled correctly proceed as given below :

3.1 Check the movement of the steering gear atthe mounting bracket, steering drop arm anddrag links (s).

Fit universal joint or flexible coupling betweensteering column and steering gear. The angledfork section must be at right angles to themarkings on steering spindle and steeringcolumns tube or valve housing in straightahead position. The angle should be the sameif two joints are used and the joint forks mustbe arranged in one plane. If it is not possibleto fit them in this way, synchronization can beachieved by positioning the forks on theserrated gearing in respect of each other.

Hammer blows on joints must be avoided incase of aluminium universal joints becausethis might lead to destruction or stiffness.Connect them by inserting the fit bolts andtightening the nuts. (Refer to the technical datafor the tightening torques).

3. Bring steered wheels to straight aheadposition.

4. Slide drop arm onto sector shaft (30), where bythe markings of drop arm and segment shaftmust coincide. Tighten hexagon nut (35)temporarily and turn steering clockwise untilwheel stop. Remove drop arm and establishwhether there is steering reserve in steeringgear box by continuing to turn steering wheel.Repeat the measurement in clockwisedirection. Tighten hexagon nut (35) to requiredtorque and secure with split pin (34) orsecuring plate (36). Hook on and tighten draglink.

5. Secure hydraulic pump on bearing block andadjust tension of the V – belt. Thumb test.

6. Connect pressure and return lines betweenpump, steering and working cylinders. If thelines have to be bent then this must be carriedout in a cold condition so that the risk ofcombustion is eliminated.

7. Commissioning the steering system

In order to prevent dirt particles which stillcould be in the system, from entering pressurelimiting valve during first commissioning, werecommend that the oil is allowed to flowthrough the system for several minutes, withchanging engine speed and without turning thesteering wheel.

Steering should then be turned several timesin both directions without completely reachingthe stops of the steering system at a mediumengine speed (until the operating temperatureis reached). It is advantageous for steeringgear boxs with a built in pressure limiting.

Finally bleed steering system (see section III).

26

POWER STEERING

XII. Vane Pump :

I. Functional description :

ZF vane pump has been specifically designed tosupply oil to hydraulic- assisted steering systems.

Low number of moving parts (drive shaft, rotor andvanes) and the minimum possible face – end playof these elements with respect to the drive – sideand cover – side faceplate ensure high efficiencyand, consequently, the best possible utilization ofpower.

This efficiency is also partially the result of thepairs of two opposite suction and pressure lines, adesign wherby the ten pump cells each conveytwice their own cell volume per revolution. Thedouble arrangement of the suction and pressurelines results in mutual cancellation of the hydraulicradial forces acting upon the rotor.

When turning the drive shaft and the rotorconnected to it, the vanes guided therin are alsodriven. Centrifugal force and pressure oil which canpass via bores and grooves from the pressurechamber on the inside faces of the rotor, force thevanes against the track of the camring. The pumpcells are thus separated from each other, causingintake as the volume rises and discharge as thevolume decreases.

Oil passes from two pressure chambers into thespace between cover and cover–side face plate,which is thus forced against cam ring at operationpressure, also to the flow – limiting valve, and viathrottle to discharge line.

An increase speed and or increase flow results inan increasing pressure drop down stream of thechoke and, consequently, on the spring side of thevalve piston.

As soon as the hydraulic force (pressure differenceX piston area) exceeds spring force, piston movesagainst spring, with the result that the superfluousconveyed oil can pass into the inlet channel ofpump via bypass bore which is then opened.

Consequently, an almost constant oil flow deliveredfor the steering gear box over entire speed range.

Maximum pressure in the pump is controlled by aspring loaded valve in flow limiting piston. Fig. 17& 18.

II. Checks :

Pump is lubricated by the hydraulic oil. It isimportant that oil level in tank be checked atspecified intervals. Oil level has to be checked withengine running in idling speed.

The trapped air is under pressure with pumprunning. Trapped air expand to atmosphericpressure when pump is shut down. This causes oillevel to rise 1 to 2 cm in tank.

Check oil level in tank before starting engine. Ifnecessary, top up oil until it is 2 cm above uppermark. Start the engine and run at idling speed. Ifoil level drops more than 1 to 2 cm, entirehydraulic system must be bled as specified.

In order to prevent air entry in the system, all hoseconnections and joints should be checked fortightness and, if necessary, retightened.

27

POWER STEERING

Fig. 17

1. Vane Pump2. Pulley3. Spring Washer4. Hex Bolt5. Bracket

XIII. SECTIONAL VIEW OF VANE PUMP

Fig.14b FunctionalRepresentation of ZFVane CP1

1. Housing2. Shaft3. Rotor4. Vanes5. Cam ring6. Rear control

7. Front control8. Suction duct9. Pressure duct10. Cover11. Pressure relief valve12. Flow control valve13. Throttle insert

Fig. 18

28

POWER STEERING

Fig. 19

S.NO DESCRIPTION / EXPLODED VIEW NO.

1 Bowl Assy. (615, 632, 607)

2 Cover Assy. (605)

3 Rubber Sleeve (636)

4 Dip Stick (601, 601.1, 601.2)

5 O' Ring Sleeve (601.1)

6 O' Ring (601.2)

7 Sealing Ring (606)

8 Filter (630, 631, 608)

9 Wing Nut (624)

10 Oil Tank Complete

XIV. POWER STEERING OIL TANK

29

POWER STEERING

a) Not enough oil in system Oil level less. Check system for leakages.

b) Air in hydraulic system. Check suction line and shaft sealing ring of pump

shaft for leakages.

c) Improper pump drive. Check belt tension / gear drive.

d) Flow control valve of pump stuck/clogged Remove control valve, wash and check. Valve

should move smoothly.

e) Filter clogged or broken. Drain oil and clean system and replace filter.

f) Stiff universal joint. Replace the universal joint.

g) Inner seals of gear box / pump damaged Gear box and pump to be repaired.

2. Hard steering in either direction of turning only.

a) Steering limiter valve responds too early Readjust steering limiter as specified.

b) Steering limiter valve does not close Remove valve and inspect.

c) Inner sealings damaged Gear box to be repaired.

d) steering spool adjustment incorrect Gear box to be repaired.

3) Hard steering when steering wheel is turned fast.

a) Pump drive defective. Retension belt / ensure proper gear drive.

b) Spool valve in pump clogged. Remove spool valve, clean and refit.

c) Pump delivering less pressure Pump to be repaired.

(wear of rotor and pressure plates)

d) Air in oil. Check suction line and pump shaft seals for

leakage. Bleed system.

4) Poor self centering of steering wheel

a) Steering column and steering Grease / oil steering column, Steering knuckles,

Linkages stiff. ball joints, stub axle etc.

b) Steering gear box centre torque high. Reset pressure point.

TROUBLES AND REMEDY :

1. Hard steering when turning steering wheel to the right or to the left.

CAUSE REMEDY

XV. Faults and Remedies :

ZF steering system is designed to meet exactingrequirements. Gear box is designed in such a waythat no faults can occur in case of correctmaintenance and normal operation.

However, if a fault should occur, before the steeringgear box is checked for individual faults, oil levelmust first be checked with engine running. Oil fillingprocedure is described in section II. Heavilyfoaming oil may lead to faults, since such oilrelease air with great difficulty or not at all, once ithas entered the system.

30

POWER STEERING

5) Inaccurate steering when driving straight ahead.

a) Not enough oil in system / air in system. External leakages in system to be arrested.

b) Air in system. Check cause of air intake and repair (specially

suction line)

c) Mounting bolts of gear box loose. Tighten bolts to specified torque.

d) Play in ball joints or steering linkages. Install new joints.

e) Play in gear box spool valves. To be repaired.

6) Severe steering wheel jerks while steering.

a) Not enough oil in system. Top up oil and check for external leakages.

b) Air in system. Check cause of air intake and repair (specially

suction line).

c) Play in gear box sector shaft. Adjust centre torque.

d) Play in ball and nut / worm of gear box. To be repaired.

7) Torsional viabrations on steering wheel ( flutter)

a) Unbalanced wheels / break drums. Wheels to be balance.

b) Steering geometry not correct. To be adjusted / corrected.

c) Air in oil. Leakages to be checked and corrected (suction

line).

8) Excessive play noticed at steering wheel.

a) Steering gear mouting bracket loose. Tighten bolts to required torque.

b) Play in universal joint. Replace joint.

c) Play on sector shaft. Adjust centre torque.

d) Play in worm and nut of gear box. To be repaired.

9) Excessive pump noise.

a) Not enough oil in system. Check for external leak. Repair and top up with oil.

b) Air in oil. Check suction line and pump shaft seal for leaks.

c) Pressure line touches frame or body Provide for adequate distance between the pipes

( noise due to direct metalic contact). and use rubber padding.

d) Pressure in suction line is too high Check for clogged suction line Clean strainer.

10) Hydraulic oil loss.

a) loose oil tank cover / dip stick. Fit the same properly.

b) Shaft seal leakage on pump/gear box Replace the seals.

c) Loose adaptors and damaged Sealing Replace sealing wahsers and tighten adaptors

washers on gear box, Oil tank and pump. / joints.

1

FUEL SYSTEM

FUEL SYSTEM

1

FUEL SYSTEM

FUEL SYSTEM

Introduction :

Fuel system consists of following components :

1. Fuel tank assy.

2. Fuel tank strainer.

3. Fuel filter (on Engine)

4. Fuel level gauge.

5. Fuel filler cap & neck.

6. Fuel hoses and fuel lines (i.e. delivery & returnlines)

Warning :

● While removing fuel tank from vehicle, keepsparks, cigarettes, and open flame away fromit.

● Before repairing fuel tank assembly, clean itthoroughly

● Always wear safety glasses.

4

FU

EL

SY

ST

EM

Fig. 1 FUEL SYSTEM : TELCOLINE SINGLE CAB

5

FUEL SYSTEM

1 - ASSY FUEL TANK COMPLETE

2 - HOSE CLIP 17

3 - RUBBER HOSE

4 - TUBE 10X0.7 THK

5 - CLAMP

6 - BRACKET

7 - RUBBER PACKING

8 - ASSY FILLER NECK WITH BKT.

9 - SEALING WASHER

10 - ASSY FUEL TANK CAP COMPLETE (DIESEL)

11 - HOSE CLAMP 60

12 - RUBBER HOSE (FOR FUEL TANK NECK)

13 - RUBBER PACKING

14 - ASSY STRAP

15 - CR PAN HD SCREW M5X10

16 - SPRING WASHER B5

17 - FUEL TANK LEVEL GUAGE UNIT

18 - SEALING RING

19 - HEX SCREW M6 X 14

20 - ASSY. SUCTION TUBE

21 - SEALING RING

22 - O-RING 31.5 X 2.65


24 - ASSY SUCTION LINE (TANK TO HOSE)

25 - PIPE CLAMP

26 - RUBBER HOSE

27 - HOSE CLIP 16

28 - SUCTION LINE (TUBE 10 X 0.7)

29 - ASSY SUCTION PIPE (HOSE TO FILTER)

30 - ASSY RETURN LINE (HOSE TO TANK)

31 - RETURN LINE (TUBE 10 X 0.7)

32 - BRACKET

33 - BRACKET

34 - CLAMP (10 OD PIPE)

35 - PLATE

36 - RUBBER BUSH

37 - CLAMP

38 - SEALING WASHER 14 X 1.8

39 - PIPE UNION BOLT 10 M14 X 1.5

FUEL SYSTEM - TELCOLINE SINGLE CAB 2825 WB

4

FU

EL

SY

ST

EM

Fig. 2 FUEL SYSTEM : TELCOLINE CREWCAB

5

FUEL SYSTEM

1 - ASSY FUEL TANK COMPLETE

2 - FUEL TANK LEVEL GUAGE UNIT

3 - SEAL RING

4 - CR PAN HD SCREW M5 X 10


6 - ASSY SUCTION TUBE

7 - SEALING RING

8 - HEX SCREW M6 X 14

9 - O-RING 31.5 X 2.65


11 - CABLE TIE 80 X 300 BLACK

12 - CLAMP (FUEL FILLING PIPE)

13 - BRACKET

14 - RUBBER HOSE

15 - HOSE CLIP 17

16 - ASSY FUEL TANK CAP COMPLETE

17 - SEALING WASHER

18 - ASSY FILLER NECK WITH BRACKET

19 - RUBBER HOSE (FUEL FILLING)

20 - ASSY PIPE (FUEL FILLING)

21 - HOSE CLAMP 80

22 - RUBBER HOSE (FUEL FILLING)

23 - BRACKET

24 - BRACKET

25 - BRACKET

26 - CLAMP (10 OD PIPE)

27 - CLAMP

28 - SUCTION LINE (TUBE 10 X 0.7)

29 - ASSY SUCTION PIPE (HOSE TO FILTER)

30 - CLAMP

31 - RUBBER BUSH

32 - BRACKET

33 - ASSY SUCTION LINE

34 - HOSE CLAMP 16

35 - ASSY RETURN LINE (HOSE TO TANK)

36 - RETURN LINE (TUBE 10 X 0.7)

37 - TUBE 10 X 0.7 THK

38 - PIPE CLAMP

39 - SEALING WASHER 14 X 1.8

40 - PIPE UNION BOLT 10 M14 X 1.5

FUEL SYSTEM - CREWCAB 3150 WB

6

FUEL SYSTEM

FUEL TANK

Fuel tank is located in front of rear axle.

Removal

1. Remove fuel tank cap.

2. Drain fuel in a container. Do not store fuel in anopen container to avoid fire or explosion. Unscrewbanjo bolt and disconnect suction line from fueltank strainer.

3. Unscrew banjo bolt and disconnect return linefrom fuel tank.

4. Disconnect fuel gauge float unit connector.

5. Disconnect the fuel filler neck and connectinghose by loosening hose clamps.

6. Loosen fuel tank mounting screws and take outthe tank .

Inspection

1. Visually inspect fuel tank for deterioration, leaksand damage. Replace tank if necessary.

Fuel tank purging procedure

1. Remove fuel tank from vehicle as above.

2. Remove strainer and float unit from tank. (Referfig. 4 & 5).

3. Shift the tank to flushing area.

4. Fill tank with warm water or normal tap waterand agitate vigorously and drain water.

Repeat the procedure until inside of tank is clean.

5. Completely flush out remaining water afterwashing & let fuel tank dry from inside.

6. Replace the fuel tank if it is rusty from inside.

Warning :

Do not allow water to remain inside fuel tank afterwashing. This will cause corrosion inside fuel tank anddamage to other parts in fuel system.

7

FUEL SYSTEM

Assembly

1. Assemble strainer and float unit to fuel tank.Assemble strainer with new 'O' ring.

2. Assemble fuel tank on vehicle with fasteners/straps. Replace rubber spacers/straps if founddeterioated, cut or perished.

3. Connect suction line to fuel tank strainer andtighten banjo bolt. Always use new sealingwashers.

4. Connect return line to fuel tank and tighten banjobolt. Always use new sealing washers.

5. Install fuel filler hose after fuel tank has beenmounted in place and tighten hose clamps. Failureto follow this caution could result in leakage offuel from hose connections.

6. Fill the tank with fuel.

7. Prime fuel system as follows :

a. Unscrew fuel lift pump plunger knob. Pull andpush it 10-15 times (30-40 times if fuel tank hasbeen completely emptied) (Refer fig. 3)

b. Tighten fuel lift pump plunger knob.

c. Start engine and check for fuel leakage. Rectifyif necessary.

d. Check for smooth running of engine. If erraticfuel supply is still felt, check for air suction infuel pipelines from fuel tank to FIP and rectify.

Fig. 3

��

10

FUEL SYSTEM

Fig. 4

Fig. 5

TELCOLINE SINGLE CAB FUEL TANK

9

FUEL SYSTEM

FUEL TANK STRAINER

Removal

1. Unscrew banjo bolt and disconnect suction linefrom fuel tank strainer.

2. Unscrew hex screws and pull out strainer.(Refer fig. 4 & 5)

Inspection

1 Check strainer mesh for clogging.

Warning :

Unless replacement of fuel tank strainer or purging offuel tank is necessary, strainer should not be removedfrom tank.

Assembly

1 Clean strainer and refit with a new 'O' ring.

2. Connect suction line to fuel tank strainer andtighten banjo bolt.

3. Always use new sealing washers.

4. Prime fuel system as mentioned above.

FUEL FILTER

Filter assembly is located in engine compartment. Itfilters the fuel sucked from tank. This is essential toavoid clogging of injector nozzle holes.

Removal

1. Unscrew drain plug and drain fuel from filter bowls.

2. Loosen banjo bolts & disconnect suction line &supply line from filter.

3. Remove filter assembly with top cover frommounting bracket.

4. Unscrew fuel filter bowl mounting bolt & removebowl with element.

Inspection

1. Check tank side filter element & FIP side filterelement for clogging, damage. Replace ifnecessary.

2. Replace tank side filter element & FIP side filterelement at recommended intervals.

10

FUEL SYSTEM

Assembly

1. Assemble new filter element if necessary.

2. Assemble fuel filter and fit it on mounting bracket.

3. Connect suction line/supply line to fuel filters andtighten banjo bolts.

4. Always use new sealing washers.

5. Prime fuel system as mentioned above.

FUEL FILLER NECK CAP

The fuel tank filler neck has a vented cap.

Removal / Inspection

1. Remove filler cap (Refer fig. 6).

2. Check 'O' ring for even filler neck imprint.

3. Check 'O' ring for any deterioration or anydamage. If found damaged replace cap.

Note :

If cap needs replacement, ensure usage of genuinecap. Otherwise it may result in malfunction of fuelsystem.

Fig. 6

��

11

FUEL SYSTEM

FUEL HOSES AND FUEL LINES

Removal

1. Unscrew all fuel hose clamps for removing fuellines & hoses. (Refer fig. 7)

2. To avoid damage to the fuel lines / hoses whiledisconnecting slide back the clamps then twistthe lines as you pull.

Caution :

a. While removing fuel pipe & hoses use wastecloth etc. to prevent spilling fuel.

b. Spilt fuel should always be wiped away.

c. After the fuel pipe & hose have been removed,install blind caps to prevent entry of foreignparticles.

Inspection

1. Visually check all hoses and pipes for leaks,loose connections, deterioration or damage,crack etc. Replace if necessary.

2. Make sure that all clamps are secured & tight.

3. If pipe clamps found deformed, bent or brokenreplace with new ones.

Assembly

1. Do not tighten clamps excessively to avoiddamage to hoses.

2. Care to be taken to connect hose to pipe andclamp on hose.

3. Do not kink twist hoses when they are routed.

4. When attaching hose to pipe, be sure that hoseis attached as shown in the Fig. 8

5. After pipes and hoses have been connected,prime fuel system, start the engine and ensurethat there is no fuel leakage.

Fig. 7

��

Fig. 8

15-20 mm

1

EXHAUST SYSTEM

EXHAUST SYSTEM

3

EXHAUST SYSTEM

Exhaust System consists of exhaust pipes, catalyticconverter and silencer. Exhaust gases emitted fromengine consists of harmful pollutants like Co, Nox,Unburnt hydro carbons & particulate matter. Two waydiesel oxidation catalytic converter reduces pollutionbefore exhaust gases are released to atmosphere,thus protecting environment.

INTRODUCTION

5

EXHAUST SYSTEM

1 GASKET

2 HEX SCREW M10 X 40

HEX NUT M10

BRIGHT WASHER 10.5

3 ASSY. EXHAUST PIPE FRONT

4 RUBBER HANGER

5 HEX BOLT M8 X 35

SPRING WASHER B8

BRIGHT WASHER 8.4

6 GASKET (CATALYTIC CONVERTER)

7 CATALYTIC CONVERTER

8 ASSY. EXHAUST PIPE (INTERMEDIATE)

9 GASKET

10 ASSY. MAIN SILENCER

11 ASSY. EXHAUST PIPE (REAR)

12 RUBBER HANGER

Fig. 1

EXHAUST SYSTEM

6

EXHAUST SYSTEM

a. Removal of Exhaust pipe front

- Unscrew bolts connecting exhaust pipe frontto manifold.

- Unscrew bolts connecting exhaust pipe frontto catalytic convertor.

Remove pipe from rear.

b. Removal of Exhaust Assembly

(Catalytic converter, silencer, intermediatepipe and tail pipe)

- Disconnect pipes one by one by removing boltsfrom joints and removing pipe hanging hooksfrom rubber hangers.

c. Tightening torques

At - Manifold end - 6.4 mkg

At - Other joints - 3.2 mkg

7

EXHAUST SYSTEM

Warning :

To avoid the danger of being burned, do nottouch the exhaust system when the systemis hot. Any service on the exhaust systemshould be performed when the system is cool.

MAINTENANCE :

At every interval of periodic maintenance service,and when vehicle is raised for other service, checkexhaust system as follows :

● Check rubber mountings for damage,deterioration, and out of position.

● Keep sufficient clearance between exhaustsystem components and underbody oradjacent parts. (min. 25 mm)

● Check exhaust system for leakage, looseconnection, dent and damage.

If bolts or nuts are loosened, tighten them tospecified torque.

● Check nearby body areas for damage, missingor mispositioned part, open seam, hole, looseconnection or any other defect which couldpermit exhaust fumes to seep into vehicle.

EXHAUST MANIFOLD

● Check gasket for deterioration or damage.Replace if necessary.

EXHAUST SYSTEM

In case exhaust pipe/silencor/catalytic convertorneeds replacement, guidelines given below shouldbe followed.

● Tighten bolts and nuts to specified torquewhen reassembling.

● After installation, start engine and check eachjoint of exhaust system for leakage.

● Exhaust silencer & catalytic converter shouldnot be subjected to impulse force by droppingit or hitting it against hard object.

Silencor

Catalytic Convertor

��

1

RADIATOR

RADIATOR

3

RADIATOR

SERVICE INSTRUCTION FOR COPPER BRONZERADIATOR

RADIATOR

Type - Maccord

Number of tubes - 126

Number of tube rows - 4

Capacity - 6 liters

Leakage testing pressure - 2 kg/cm2

RADIATOR CAP

Pressure valve opening - 1.0 kg/cm2

Vacuum valve opening - 0.05 kg/cm2

REMOVAL OF RADIATOR FROM VEHICLE

Note : Before proceeding for removal of radiator ensurethat cooling system is at room temperature.

Remove radiator cap.

Drain coolant from cooling system through radiatordrain cock.

Fit back radiator cap and drain cock.

Remove hoses :

- Radiator to water pump.

- Radiator to upper cooling line.

Disconnect pipe from radiator to auxiliary tank.

Remove fan shroud bottom and top halves.

Check fan shroud for cracks, damage etc.

Replace if necessary.

Loosen/remove radiator mounting bolts. Now radiatorcan be removed from vehicle.

INSPECTION AND CLEANING

Cleaning

Fit radiator cap.

Close radiator drain cock firmly. Refer Figure 1.

Place radiator upside down on ground.

Connect water supply line to radiator bottom tankat its outlet.

Slowly increase water supply to radiator .Maximum

pressure in system should not exceed 1.0 bar.

Continue water flow till outlet water is visually cleanand clear.

Fig. 1

Remove connection made for cleaning.

Remove radiator cap and suitably plug inlet andoutlet of radiator.

Completely fill radiator with measured quantity ofwater. If radiator capacity is less than specified itreflects chocked tube.

Reclean / de-scale radiator using suitable cleaningcompound as per manufacturer’s instruction.

Fit back radiator cap.

Blow compressed air through radiator fins fromengine side to clean air passages.

Do not brush or scrape radiator core in any way.

Testing for leaks

Remove radiator cap.

Suitably plug radiator inlet, outlet and filling neck.

Remove radiator drain cock adapter.

With suitable adapter connect pressurised airsupply to radiator drain cock hole.

Submerge radiator in water tank.

Admit air at 1.0 bar (max) into radiator.

Check for leaks and if any suitably mark them.

Take out radiator from water tank.

Disconnect air supply connections.

Remove all plugs. Rectify leaks by soldering

Recheck radiator for leakage.

Fit back radiator drain cock adapter.

Fit back radiator cap.

4

RADIATOR

Instruction for soldering Copper-Brass Radiator

Use 40% tin content solder. This solder has highertin content and hence lower melting temperaturethan used in manufacture of radiator. Use of thiswill not have any effect on original soldering nearby.

Use non corrosive fluxes for soldering. Neutralizeand wash residues to avoid any consequentdamage. Acid should not be used for this purpose.

SERVICE INSTRUCTION FOR ALUMINUMRADIATORS

1 Introduction

This manual explains the procedure for servicingof Aluminum Radiators with plastic tanks.Following aspects are covered:-

� Leakage spot detection

� Sealing Techniques

� Confirmation of proper sealing

2 Procedure for Servicing

2.1 Removal of Radiator from Vehicle

� Allow coolant in radiator to reach to roomtemperature

� Drain the coolant from radiator completely.Refit drain cock & radiator cap on radiator.

� Remove the hoses.

� Take out the radiator from vehicle carefully.

CAUTION : Radiator core and plastic tanks aresusceptible to cracking due toimpact and deformation

2.2 Detection of Leakage Spot

� Connect inlet of radiator to air supply atgauge pressure of 1.5 bar

� Seal all other outlet points

� Dip radiator completely in a clean water tank

� Tilt radiator and shake it vigorously to letthe air bubbles trapped at the clinchingarea to escape

� Observe carefully for one minute and locate

the source of air leakage from the directionof air bubbles that are coming out of radiator

� If Leakage spot is at radiator core thenfollow procedure given at Sr. No. 2.3 toseal leakage

� Else if Leakage spot is found at Tank or itsaccessories then follow procedure given atSr. No. 2.4 to seal leakage

CAUTION : Do not use water tank that is usedfor copper radiator

2.3 Sealing Leakage at Radiator Core

Different procedure of sealing shall be followedfor MINOR and MAJOR leaks in radiator core.

MINOR LEAKS : Leak spots which are veryminute are to be sealed infollowing manner

� Install radiator on vehicle as explainedSr. No. 3 (Radiator Installation)

� Pour contents of ALUMASEAL in radiator

� Fill proper quantity of coolant liquid

� Run engine in idling speed for 20 minutes

MAJOR LEAKS : Procedure of sealing majorleaks in radiator is asfollows :

� Wash core with clean water and brush toremove dirt, dust etc.

� To remove greasy spot on core, applythinner with cotton swab and take off grease

� Dry core using a dryer (Do not use heatingsource)

� Mix adequate quantity of ARALDITERESIN(Araldite rapid may be used in placeof Araldite standard for faster drying &curing of seal) and HARDENER in the ratioof 1:1 and stir it thoroughly

� Apply the mixture immediately at theleakage spot with applicator

� Allow the mixture to dry and harden underthe shade at room temperature for 10-12hour

� Silver color paint may be used for touching

5

RADIATOR

� Silver color paint may be used for touchingup araldite spots and impart aluminum typeappearance

NOTE : Araldite Rapid of M/s Ciba Geigy dries& hardens within one hour & henceusers may use it to minimize downtime

CAUTION :

� Do not damage the fins during process.

� As the Araldite is inflammable do not dry itby using any heating source.

� Proper cleaning of leakage area is mustfor proper setting of Araldite or else it willcome off.

2.4 Servicing of Tank and its accessories

� If the source of leakage is tank, then replacethe tank

� Take out the member support using correctsize spanner

� Remove the tabs of the header plate usingscrew driver and monkey plier

� After making all clinching projections up,take out the tank from its seat in headerplate

� In case it takes more effort, pat the tankwith rubber or plastic hammer lightly

� Take of the tank packing

� Clean the area of header plate where tanksits thoroughly

� Insert new tank packing in place withouttwisting

� Clinch the header plate projections withmonkey plier

� After clinching confirm dimension of headerplate height as 10.2 to 10.6 mm

� Fix the member support & tighten boltsproperly

CAUTION :

� Tank packing shall be replaced every time,when the tank is taken off for servicing.

� If any of the clinching projections is brokenduring clinching or releasing process,discontinue servicing & replace entireradiator by a new one.

2.5 Servicing of Pipe Component, Drain cock &pressure cap

� Replace ‘O’ rings of these component,clean the component while reassemble

� Replace pressure cap with new one ifleakage is through even after cleaning fillerneck

2.6 Confirmation of Proper Sealing

� After the sealing work is over, assembleradiator properly

� Subject the assembled radiator to leakagetest as per Sr.No. 2.2

CAUTION : If the problem of leakage persists,it is advisable to replace radiatorwith new one

3 Radiator Installation

� Ensure that all the openings of radiator areclosed properly except the inlet / outlet

� Install radiator on the vehicle ensuringproper alignment, damping etc. asapplicable

� Connect inlet and outlet pipes and clampthem properly, Fit fan shroud etc.

� Fill radiator with proper quantity of freshcoolant as recommended

6

RADIATOR

(VACUUM VALVE)

Pressure valve openingpressure 0.9+ 0.15 kg/cm2 (gauge)Vacuum valve openingpressure < 0.05 kg/cm2 Max

Checking cap (Refer Figure 2)

Check radiator cap for perfect sealing in filler neck.

Check radiator cap, main and vacuum valve openingpressures.

Replace defective cap with new one of recommendedrating.

Test for main valve opening pressure.

Radiator cap shall be tightened after filling in with water.Water inside the radiator is pressurised. Check thatmain valve opens at specified pressure of 1.0 kg/cm2

Radiator cap main valve should not open belowspecified pressure.

On the vehicle, functioning of radiator cap main valvecan be checked by observing increase in coolant levelin auxiliary tank at high coolant temperature.

Test for vacuum valve opening-

Radiator cap shall be tightened without water insideradiator and shall be connected to vacuum pump.Check that vacuum valve opens fully at 0.05 kg/cm2

vacuum.

On the vehicle, functioning of radiator cap vacuumvalve can be checked by observing decrease incoolant level in an auxiliary tank when it cools downcompared to higher level at high temperature.

FITMENT ON VEHICLE

Fit radiator.

Fit fan shroud top and bottom halves.

Fit hoses

- Radiator to water pump

- Radiator to upper cooling line

Connect tube from auxiliary tank to radiator.

Close radiator drain cock firmly.

Fill coolant (clean water blended with anti freeze agentas per recommendation).

Fit radiator cap.

Top up coolant through auxiliary tank cap upto ‘MAX’

mark.

RUN ENGINE FOR SHORT DURATION AND TOP UPCOOLANT IF NECESSARY.

Fig. 2

1

ELECTRICAL

ELECTRICAL

3

ELECTRICAL

Electrical system incorporates a number ofspecial accessories apart from standard ones.There is one Electronic Control Unit (ECU) withdiagnostic capabilities for Transfer Case(4x4 version).

Wiring diagrams and schematic electrical circuitsincluded in this manual are only for guidanceduring trouble shooting. Due to continuousimprovements on the product, actual wiring layout,locations of components and connectors, wirecolour codes etc. may change.

INTRODUCTION

5

ELECTRICAL

CONTENTS


1 Technical specifications 7

2 Circuit diagram symbols 8

3 Wire colour coding 9

4 A) List of bulbs 9

B) List of relays 9

5 List of bulbs fuses 10

6 Alternator 11

7 Starter motor 31

8 Switches, lamps & other components 33

A – Steering lock cum ignition switch 33

B – Combination switch RHD 34

C – Combination switch LHD 36

D – Combination switch – fitment, removal & testing 38

E – Piano switches 38

F – Gauges & indicators – functional details 39

G – Instrument Cluster 41

H – Trouble shooting chart for gauges & instruments 43

I – Gauges & indicators - fitment, removal & testing 44

J – Headlamps & Tail Lamp – removal & fitment 45

K – Trouble shooting chart for lamps 46

L – Horn - fitment, removal & testing 49

9 Control Units

A – Buzzer unit 50

B – Chime unit 51

C – Flasher unit 52

D – Glow plug timer 53

E – Front wiper controller 55

F – EGR controller 56

10 Central locking system 57

11 Electronic control unit – Trouble shooting for 4X4 operation 59

12 Windshield wiping & washing system 62

13 Additional fitments 75

14 General trouble shooting guidelines 76

15 Wiring diagrams – locations, connection, routing, circuit diagrams 77

7

ELECTRICAL


Battery : 12 V, MF 70 Z

Capacity : 75 Ah (20 Hr rating)

System voltage : 12 Volts (–ve earth)

Alternator capacity : 75 Amps for AC +Heating demistingvehicle

65 Amps for heatingdemisting vehicle

Head lamp : Semi sealed Europeanbeam asymmetricalpattern with halogenlamp, Built-in frontparking light.

Wind screen washer : 2 speed with intermittentwiping.

Steering lock cum : Standard fitmentIgnition switch with key in sensor

Combi switch : With self cancelling turnsignals and hazardwarning switch.

Instruments : a) Speedometer (km/hr)and odometer (km) & tripmeter (km)

b) Fuel gauge with lowfuel level indicator (LED)

c) Water temperaturegauge

d) Engine RPM meter

Indicator lamps : For battery charging, lowoil pressure, directionindicator, main beam,brake fluid level + handbrake and glow plugtimer and hazardwarning.

4x4 high and 4x4 lowmode indicators for 4x4vehicles.

Tail lamp : Four function tail lampand separate reflexreflector at rear.

Other features 1. Blinkers on side bonnet.2. Two Roof Lamps for TMCC3. Provision for radio/

cassette player.4. Rear number plate

lamps.

8 EL

EC

TR

ICA

L2. CIRCUIT DIAGRAM SYMBOLS

9

ELECTRICAL

Code Colour Name

Lg Light Green

Dg Dark Green

Sb Sky Blue

P Pink

V Violet

O Orange

W White

L Blue

Br Brown

Gr Grey

G Green

Y Yellow

B Black

R Red

Note : Wire insulator has one colour or one maincolour with another tracer colour stripe. (e.g. ‘L’ indi-cates blue colour. ‘L-W’ indicates blue main colourwith white tracer colour stripe)

3. WIRE COLOUR CODING

Description Cap Type Specs Qty.

Head Lamp – Halogen H4 P43t 12V, 60/55 W 2

Front Direction Indicator BAU15s 12V, 21W 2

Side Repeater Indicator W2.1 X 9.5d 12V, 5W 2

Tail Lamp – Rear Direction Ind. BA15s 12V, 21W 2

Tail Lamp – Rear Stop BA15s 12V, 21W 2

Rear Registration Lamp BA15s 12V, 10W 2

Tail Lamp – Rear parking BA15s 12V, 10W 2

Parking Lamp – Front BA9s 12V, 4W 2

Tail Lamp – Reverse Lamp BA15s 12V, 21W 2

4A.LIST OF BULBS

1] AC condenser fan relay (on vehicle with AC)

2] AC cut off relay (on vehicle with AC)

3] Auxiliary relay

4] Starter relay

5] Ignition relay

6] Glow plug timer relay

7] Head lamp low beam relay

8] Head lamp high beam relay

9] Parking relay

10] Horn relay

11] Rear fog lamp relay

12] Rear glass demist relay

4B.LIST OF RELAYS :

10

ELECTRICAL

5. LIST OF FUSES

11

ELECTRICAL

6) ALTERNATOR:

Removal :

❑ Disconnect battery earth lead.

❑ Loosen nut securing cable to alternator andrelease cable.

❑ Disconnect other connections from alternator.

❑ Remove nut and bolt securing alternator toadjustment bracket.

❑ Loosen bolt securing alternator to engine.

❑ Release drive belt tension by turning thetension adjusting bolt anti-clockwise.

❑ Release drive belt from alternator pulley.

❑ Remove nut and bolt securing alternator toengine.

❑ Release alternator from bracket and removealternator.

Fitment

❑ Position alternator to engine and locate insupport bracket.

❑ Fit nut and bolt securing alternator to engine,but do not tighten.

❑ Clean pulley vee‘s.

❑ Locate drive belt to alternator pulley. Ensuregrooves on drive belt and pulleys are correctlylocated.

❑ Fit nut and bolt securing alternator toadjustment bracket.

❑ Adjust drive belt tension.

❑ Connect all connections including cable toalternator, fit and tighten cable nut.

❑ Connect battery earth lead.

Testing / Checking

Please refer 3SA23 alternator service details

Electrical Circuit Diagram for Starting, Chargingand Engine Stop Solenoid may also be referred.

Fig. 1

Fig. 2

12

ELECTRICAL

TYPICAL PERFORMANCE CURVE

GENERAL DESCRIPTION

The 3SA23 Alternator (65 Amps) and 3SA28 Alternator (75 Amps) with vacuum pump is intended for use onlight commercial vehicles and similar automotive applications. This alternator is suitble for negative earth system.

This section deals with 3SA23 Alternator.

◆◆◆◆◆ Do ensure that all electrical connectionsare clean and secure.

◆◆◆◆◆ Do ensure that no electrical connection inthe circuit including the battery is open.

◆◆◆◆◆ Do observe correct polarity. i.e. connectnegat ive to negat ive and posi t ive topositive. Otherwise, Alternator will bedamaged.

◆◆◆◆◆ Disconnect all alternator terminals, whilecarrying out welding jobs on vehicle.

◆◆◆◆◆ Disconnect battery ear th cable beforeremoving alternator.

◆◆◆◆◆ It is advisable to replace a new ‘OIL SEAL’in SRE Bracket, whenever alternator isdismantled for service.

DO'S � DONT'S �

ALTERNATOR

◆◆◆◆◆ DO NOT DIS-ASSEMBLE ALTERNATORWITHOUT REMOVING BRUSH BOXASSEMBLY.

◆◆◆◆◆ Do not flash alternator output leads tocheck the working of the alternator.

◆◆◆◆◆ Do not run a l ternator w i th bat terydisconnected.

◆◆◆◆◆ Do not disconnect any lead of Alternator/Regulator with engine in running condition.

◆◆◆◆◆ Do not disconnect battery cables whileengine is running.

◆◆◆◆◆ Do not run the alternator with vacuumpump without oil. Running without oil maydamage oil seal in SRE bracket.

ALTERNATOR

Fig. 3

13

ELECTRICAL

VACUUM PUMP VACUUM PUMP

◆◆◆◆◆ Remove vacuum pump from alternatorbefore any electrical running tests.

◆◆◆◆◆ Whenever vacuum pump is removed foralternator, the ‘O’ r ing (small) must be

renewed.

◆◆◆◆◆ I f a l ternator is to be dis-assembled,serrations of rotor shaft must be coveredto avoid possible damage to serrations.

◆◆◆◆◆ Ensure oil feeding pressure at 3 kg/cm2

and flow rate 0.5-1.0 litre/minute at 5000RPM.

◆◆◆◆◆ Ensure proper tightening torques of oilhoses and vacuum hoses to avoid oil orair leakage.

◆◆◆◆◆ When refitting vacuum pump, it may benecessary to tilt it, in order to centralisethe floating inner driven member, beforesliding the assembly on to the splined rotorshaft.

◆◆◆◆◆ Oil pump should not be run, if the alternatoris not running. (e.g. engine is running butbelt not fixed).

◆◆◆◆◆ Do not run pump without oil.

◆◆◆◆◆ Do not use any oil other than SAE-30 for

testing. NOTE : Use an oil filter.

◆◆◆◆◆ Do not mount alternator close to exhaustmanifold without any protection.

ROUTINE MAINTENANCE

◆◆◆◆◆ Keep the alternator clean.

◆◆◆◆◆ Ensure that the ventilation slots are clear.

◆◆◆◆◆ Check and ensure that mounting bolts are tightened properly.

◆◆◆◆◆ Check and ensure that hoses are connected to vacuum pump.

◆◆◆◆◆ Ensure that there is no leakage of air and oil.

◆◆◆◆◆ Ensure that the alternator belt is in good condition.

◆◆◆◆◆ Check belt tension and ensure that it is neither too slack nor too tight.

◆◆◆◆◆ Adjust belt deflection to 10-15mm when pressed out midway of the longest point between pulleys.

◆◆◆◆◆ Check brush length periodically & replace brush if necessary.

◆◆◆◆◆ Ensure correct battery electrolyte level.

◆◆◆◆◆ Check general condition of battery.

◆◆◆◆◆ Grease battery terminals with petroleum jelly.

DO'S � DONT'S �

14

ELECTRICAL

TECHNICAL DATA

1. Type 3SA23

2. Rating Continuous

3. Battery Voltage 12 V

4. Nominal Output 65 A

5. Weight 6.6 Kg. Approx. (Including Pump & Pulley)

6. Rated Maximum Output Speed 6000 R.P.M

7. Speed 1000 to 10,000 R.P.M.

8. No. Of Poles 12

9. Over Speed with Maximum Output 11000 RPM for 1.0 Minute

10. Polarity Negative Earth

11. Regulating System Bult-In Regulator

12. Reg. Set Voltage 14.0 ± 0.2 V

13. Direction of Rotation Clockwise (Viewed from Pulley end)

ALTERNATOR

1. Type of Vacuum Pump Vane Type

2. Capacity of the Pump 30 CC/REV.

3. Operating Condition(a) Speed 1000 to 11,500 RPM

(b) Ambient Temperature - 30OC to + 80OC

(c) Oil Feeding Pressure 1.0 to 3.0 kgf/cm2

(d) Lubricating Oil SAE 30

(e) Rotation Clockwise (Viewed from Drive end)

(f) Oil Temperature 75O ± 5OC

4. Exhaust Characteristics

Test Specifications

(a) Speed 1000 RPM 5000 RPM

(b) Time 35 SEC MAX. 10 SEC MAX

(c) Vacuum 500 mm Hg. 500 mm Hg.700mm Hg. at 5000 RPM Under oil Feeding

5. Maximum Attainable degree of vacuum Presssure of 1Kgf.cm2 and oil temperatue of

75O ± 5O C Conditions.

6. Vacuum Drop Vacuum drop 20mm Hg. max. in 15 secs.(After stoppage of pump at 400 mm Hg.)

VACUUM PUMP

15

ELECTRICAL

NOTE :

◆◆◆◆◆ Performance value to be taken after one hourhot run at 6000 RPM and 40 AMPS. (Hot runis to be conducted with regulator in circuit)

◆◆◆◆◆ Ambient temperature 27O C to 32O C.

◆◆◆◆◆ Starconnected 3-phase output winding woundon a laminated stator.

◆◆◆◆◆ 12-pole wound field rotor, carried on ball-racebearings in aluminium end brackets and beltdriven from engine.

◆◆◆◆◆ Self-excited field (via three field diodes) atnormal running speeds.

◆◆◆◆◆ RA65 recif ier provides recti f ication ofgenerated A.C

WIRING DIAGRAM FOR TESTING ALTERNATOR

SALIENT FEATURES OF 3SA23 ALTERNATOR :

◆◆◆◆◆ Voltage control is provided via a built-inelectronic regulator.

◆◆◆◆◆ An RFI suppression capacitor is providedacross positive and negative terminals.

◆◆◆◆◆ As a safeguard against accidental reversebattery connections, a fuse is provided.

◆◆◆◆◆ A spare fuse is also provided.

◆◆◆◆◆ A phase connection can be made available ifrequired.

◆◆◆◆◆ Cut-In speed at 13.0 Volt at terminals to be1000 RPM (Cold)

WIRING DIAGRAM

Fig. 4

Fig. 5

16

ELECTRICAL

ALTERNATOR CHARGING SYSTEM CHECKS ON THE VEHICLE

BEFORE STARTING CONDITION

NO

REMOVE THE ALTERNATORAND CHECK REGULATOR

CHECK WARNING LAMP FOR ANY DEFECT.CHECK "WL" TERMINAL IN ALTERNATORFOR PROPER CONNECTION.

CHECK THE BELT TENSION. IF FOUND SLACKADJUST THE BELT DEFLECTION TO BE 10-15mm WHEN PRESSED MIDWAY AT THELONGEST POINT BETWEEN PULLEYS(REFER FIGURE BELOW) AND CHECK FORCHARGING. IF THE UNIT IS STILL NOTCHARGING REMOVE THE ALTERNATOR ANDCHECK.

SWITCH ON THE IGNITION

ALTERNATOR FOUND ACCEPTABLE

REMOVE THEALTERNATOR AND CHECK

�NO

�

YES

�

YES

�NO

DOES WARNINGLAMP GLOW ?

RUN THE ENGINE AT IDLE SPEED

IS RATEDCURRENT OUTPUT

REACHED WITHOUT VOLTAGEDROPPING BELOW

13.5 VOLTS ?

�DOES WARNINGLAMP GO OFF ?

NO

�YES

DOESTHE VOLTMETERREAD BETWEEN

14.0 TO 14.8 VOLTS ?

ENSURE THAT THE AMMETER READING ISLESS THAN 20A. INCASE THE BATTERYIS DISCHARGED ALLOW CHARGING OFBATTERY TILL THE AMMETER READINGCOMES TO LESS THAN 20A. CONNECT THEVOLTMETER ACROSS THE ALTERNATORMAIN TERMINALS. CHECK THE VOLTMETER READING

RAISE THE ENGINE SPEED TOAROUND 2800 ± 200 RPM.

SWITCH "ON" THE HEADLAMP PARKING LAMP,TAIL LAMP AND OTHER ELECTRICAL LOADSEXCEPT HEATER.

�YES

17

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ICA

LEXPLODED VIEW

Fig. 6

18

ELECTRICAL

SPARE PARTS LIST

DESCRIPTIONSL.NO.

1. PULLEY NUT 1

2. SPRING WASHER (PULLEY) 1

3. PULLEY 1

4. FAN 1

5. PULLEY COLLAR 1

6. FIXING BOLT 4

7. INSERT (TOP) DE 1

8. INSERT (BOTTOM) 1

9. DE BRACKET ASSEMBLY 1

10. DE BALL BEARING 1

11. BEARING RETAINER PLATE 1

12. FIXING SCREW 3

13. COLLAR 1

14. KEY 1

15. ROTOR ASSEMBLY 1

16. BALL BEARING SRE 1

17. SLIP RING 1

18. STATOR ASSEMBLY 1

19. CAPACITOR ASSEMBLY 1

20. INSUL BUSH 1

21. SRE BRACKET ASSEMBLY 1

22. SCREW (COVER PLATE) 2

23. COVER MOULDING PLATE 1

24. SPARE FUSE 1

25. CAPITAL SCREW 2

26. INSUL BUSH 1

NO.OFF DESCRIPTION

SL.NO.

NO.OFF

27. REG. & BRUSH BOX ASSY. 1

28. BRUSH SET 1

29. BRUSH SPRING 2

30. STUD 1

31. FUSE LINK 1

32. NUT 2

33. SCREW (CENTRE PLATE) 3

34. SCREW SUCTION 1

35. WASHER 1

36. CONNECTOR SUCTION 1

37. WASHER 1

38. CHECK VALVE SUCTION 1

39. SCREW VAC. UNIT FXG. 3

40. VACUUM VALVE SUCTION 1

41. WASHER 1

42. CONNECTOR DELIVERY 1

43. “O” RING (LARGE) 1

44. “O” RING (SMALL) 1

45. CUP WAHSER 1

46. INSUL WASHER 1

47. INSERT SRE 1

48. “O” RING 1

49. INSUL BUSH 1

50. RECTIFIER ASSEMBLY 1

51. EARTH LINK 1

19

ELECTRICAL

Fig. 7

Fig. 9

Fig. 8

DISMANTLING

Before dismantling, note down the position of variousparts, in order to ensure their proper replacement onre-assembly.

Drian oil from the vacuum pump, and manually rotatethe fan belt clock wise to discharge any oil whichmight have accumulated in vacuum pump.

Follow step by step procedure mentioned below

❑ Remove three f ix ing screws secur ingvacuum pump to SRE bracket. Ref. Fig. 7.

❑ Pull the vacuum pump assembly, away fromalternator.

❑ Place vacuum pump in a clean polythenecover and seal it properly.

❑ Tape the rotor shaft serrations to avoiddamage to SRE bracket oil seal while pullingit out.

Ref. Fig. 8.

DISASSEMBLY OF BRUSH BOXASSEMBLY

NOTE: Do not remove rotor assembly withoutremoving brush box assembly. Otherwise,brushes will break.

❑ Remove cover plate fixing screws (2 Nos.)Ref. Fig. 9.

20

ELECTRICAL

Fig. 10

Fig. 12

Fig. 11

❑ Remove regulator cum brush box fixingscrews (2 Nos.)

Ref. Fig.10.

❑ Lift the regulator cum brush box assembly.

DISASSEMBLY OF SRE BRACKETASSEMBLY

❑ Remove the through bolts (4 Nos.) securingDE bracket and SRE bracket.

Ref. Fig.11.

❑ Protect pump seat ing surface of SREbracket by using appropriate protective cap.

❑ Separate DE protective bracket assemblyfrom stator assembly using a wooden mallet.

Ref. Fig.12.

❑ Place SRE bracket assembly in a cleanpolythene cover.

21

ELECTRICAL

Fig. 13

Fig. 15

Fig. 14

❑ Push down rotor assembly from DE bracketusing a fly press.

❑ Cover slip ring with a suitable protectivecap.

Ref. Fig.14.

❑ Unscrew the rataining plate fixing screws(3 Nos.) and place DE Bracket assembly ina fly press and press down ball bearing fromDE Bracket as shown.

Ref. Fig. 15.

❑ Clamp rotor assembly in a soft jaw andremove pulley nut.

Ref. Fig.13.

DISASSEMBLY OF DE BRACKETASSEMBLY

REMOVAL OF DE BEARING

22

ELECTRICAL

Fig. 16

Fig. 18

Fig. 17

Remove fuse assembly.

❑ Remove the nuts holding rectifier assembly

Ref. Fig.18.

❑ Remove the RFI CAPACITOR fixing nut.

❑ Cover the oil seal portion with a protectivecap to avoid dust entry.

❑ Note down the position of stator outputleads.

❑ De-solder stator leads from rectifier.

Ref. Fig.16.

DISASSEMBLY OF STATORASSEMBLY FROM SRE BRACKET

DISASSEMBLY OF RECTIFIERASSEMBLY

Remove stator assembly.

❑ Remove earth link fixing screw

Ref. Fig.17.

23

ELECTRICAL

Fig. 19

Fig. 21

Fig. 20

❑ Clean slip ring surface with a fine piece ofcloth and ensure that the surface is smoothand clean.

Ref. Fig.21.

If the surface is very rough and cannot bepolished replace rotor assembly. There shouldnot be any trace of oil or grease on slip ringsurface.

REMOVAL OF OIL SEAL

NOTE : It is advisable to replace a new oil sealwhenever it is removed from SRE Bracket, witha special tool.

BENCH INSPECTION

ALTERNATOR

On dismantling the unit conduct following checksBrush Check

Exposed brush lengthNew brush length 27.5 mmMinimum required length 20.5 mm

Ref. Fig.20.

If brushes are below minimum required lengthrenew the brushes in sets not individually.De’solder brush leads. INSERT New brushes andsolder to maintain required brush length. Makesure that the brushes move freely inside brushbox.

SLIP RING CHECK

❑ Using a sharp pin, push the oil seal fromSRE bracket rear end.

Ref. Fig.19.

24

ELECTRICAL

Fig. 22

Fig. 24

Fig. 23

ROTOR GROUND TEST

❑ Using 230 volt AC mains supply, connect a15W bulb as shown in fig. Connect one ofthe probes to slip ring and the other to shaft.Lamp should not glow. If lamp glows itindicates earthing. Replace rotor assembly.

Ref. Fig.23.

STATOR INSULATION TEST

❑ Using 230 volt AC mains supply, connect a15W bulb. Connect one probe to any of thethree leads and other probe to body. Lampshould not glow. If lamp glows it indicatespoor insulation. Replace stator assembly.

Ref. Fig.24.

BEARING CHECK (SRE & DE)Bearings should rotate freely without anyexcessive play.

If play is observed, bearings should be replaced.

SRE bearing has a special retaining ring whichshould not be replaced or re-assembled.

ROTOR ASSEMBLY CHECK

RESISTANCE CHECK

❑ Use Ohm meter 0-10 Ohm range andconnect as shown in fig.

Connect the probes of the meter to slip ring.Value should be between 2.8 and 3.2 Ohms.If value is outside this limit, change rotorassembly.

Ref. Fig.22.

110V

110V

25

ELECTRICAL

Fig. 25

Fig. 27

Fig. 26

RECTIFIER ASSY. CHECK

Remove rectifier assembly from the unit andcheck as follows using a multimeter with twoprobes as shown in fig.

(a) Test ing posi t ive heat s ink diodes(Continuity check)

❑ Connect as shown in fig. use multimeter withtwo probes. Connect the positive probe ofmul t imeter to pos i t ive heat s ink andnegative probe to phase connecting pointson rectifier. It should not indicate opencircuit. Replace rectifier assembly if it isopen circuit.

Ref. Fig.27.

❑ Use Ohm meter with two probes connectbetween 1 and 2 leads. The value shouldread around 0.12 Ohms. Repeat it between2&3 and 3 & 1 leads.

Ref. Fig.25.

❑ Use authorised test equipment for checkingRegulators and test as per instructionsgiven in the test equipment manual.

Connect the equipment as per the markingson the regulator

Ref. Fig. 26.

STATOR WINDING RESISTANCECHECK

REGULATOR CHECK

26

ELECTRICAL

Fig. 28

Fig. 30

Fig. 29

(b) Testing Positive Heat Sink Diodes (NoContinuity check) :

❑ Connect as shown in fig. Use multimeterwith two probes.

Connect negative probe of multimeter topositive heat sink and positive probe tophase connector po in ts on rect i f ie rassemblies. All diodes should indicate nocontinuity. If there is continuity it indicatesshort circuit. Replace rectifier assembly.

Ref. Fig. 28

(c) Test ing negat ive heat s ink diodes(Continuity check) :

❑ Connect as shown in fig. Use multimeterwith two probes.

Connect positive probe of multimeter tophase connecting point and negative probeto rectifier body. All diodes should indicatecontinuity. If not, it indicates open circuit.Replace rectifier assembly.

Ref. Fig.29

(d) Testing negative heat sink diodes (NoContinuity check) :

❑ Connect as shown in fig. Use a multimeterwith two probes.

Connect negative probe of multimeter tophase connecting points and positive probeto rectifier body. Now all diodes shouldindicate no continuity. If not, it indicatesshort circuit. Replace rectifier assembly.

Ref. Fig. 30

27

ELECTRICAL

Fig. 31

Fig. 32

(e) Testing of auxiliary diodes(Continuitytest) :


Connect positive probe of multimeter to thefield plate, and negative probe to the phaseconnection on rectifier. When the startor faceleads or connect all diodes should indicatecontinuity. If not replace rectifier assembly.

Ref. Fig. 31

(e) Test ing of auxi l iary diodes (NoContinuity test) :


Connect negative probe of multimeter withthe field plate, and positive probe to thephase connecting leads. It should indicateno cont inu i ty. I f not rep lace rect i f ie rassembly.

Ref. Fig. 32

Fig. 33

Place Rotor assembly on the base of wheel pressand press down Ball bearing on to the shaft todimension mentioned in Fig. 33.

SRE BALL BEARING ASSEMBLY

28

ELECTRICAL

Fig. 34

Place SRE Bracket on the base of wheel press andpress down oil seal into SRE Bracket assembly alongwith a locking disc.

Note the position of oil seal.

Ref. Fig. 34

OIL SEAL ASSEMBLY

It is a reverse order of dismantling procedure. Notefolowing precautions.

❑ Use only 40-60 grade solder for soldering

❑ Use 65 watts soldering iron.

❑ Cover shaft serrations with a tap whileassembling Rotor assy.

❑ Remove tape from shaft serrations afterRotor assembly.

❑ Ensure t ightening torques to specif iedvalues given in the chart.

RE-ASSEMBLY

TIGHTIENING TORQUE DETAILS

DESCRIPTION VALUE

SHAFT NUT (M16) 70 ± 5. Nm

FIXING BOLTS (M5) 5.0 - 5.7 Nm

+ VE OUT PUT TERMINAL NUT (M6) 3.9 - 5.1 Nm

COVER MOULDING FIXING SCREEN (M5) 2.5 - 3.0 Nm

VACUUM PUMP FIXING SCREEN (M6) 5.8 - 6.8 Nm

29

ELECTRICAL

1. Warning light does not appear (a) If bulb does not light,when ignition switch is on. ground WL terminal of

alternator.

(b) If bulb now lights thecauses are :

(ii) Jammed brushes or brush Free brushes, Replace , iflead adrift. necessary.

(iii) Dirty slip ring Clean slip ring.

(iv) Rotor open circuit. Check that the ends of the rotor(v) Yellow lead connecting winding are soldered properly to

rectifier to regulator open. slip ring terminals. Resolder thewindings, if open, or replace therotor.

(c) If the bulb does not lighteven after grounding WLTerminal, the causes are :

(vi) Fused warning lamp bulb. Check for short circuit, if any, inthe wiring harness. Afterrectifying the short replace bulb.

(vii) Short circuited warning Replace Holder.lamp holder.

(d) If still WL does not appear Replace regulator.when Ignition switch is on,the cause is faulty Regulator.

2. Warning lamp glows dim (i) High resistance in warning Check and correct.lamp

(ii) Regulator defective. Replace Regulator.(iii) Rotor defective. Replace Rotor.

3. Warning lamp 'on'. Ammeter (i) Loose belt. Tighten the belt to the limits asshows no charge while indicated in routineengine is running. maintenance.

(ii) Aux. diode lead 'A' open. Check diode connection andtrace short. Rectify if possible orreplace rectifier assembly.

(iii) Shorted rotor Replace rotor.(iv) Stator open/shorted Replace stator assembly.

4. Warning lamp 'on' or dim but (i) Faulty bridge. Replace defective heat sink assy.ammeter shows charges (lowoutput)

5. Warning lamp goes off. (i) Faulty rectifier bridge. Replace defective heat sink assy.Ammeter shows low output

(ii) Stator winding short. Rectify or replace stator assembly

6. Warning lamp (Ammeter) (i) High resistance in Check connections and ensureflickers considerably. Negative line. use of recommended wire.

(ii) Slip ring dirty. Clean the slip ring and recheck.

7. Overcharging (battery gases) (i) Faulty regulator. Replace regulator.(ii) Rotor shorted to earth on Rectify or replace rotor assembly

negative side.

TROUBLE SHOOTING

DEFECT CAUSE REMEDY

Before starting trouble shooting ensure the battery condition

30

ELECTRICAL

31

ELECTRICAL

7) STARTER MOTOR:D7 R24 Valeo Starter Motor are being fitted atpresent on Telcoline vehicle.

SPECIFICATION :

Voltage : 12V

Weight : 3.81 kg

Battery Terminal : M8 x 1.25

Exitation Terminal : V1SHM5

No. of teeth of pinion : 10

Pressure angle for pinion : 20O

Teeth on ring gear : 136

REMOVAL

❑ Disconnect battery cable from star tersolenoid.

❑ Remove nut securing battery cable to startersolenoid.

❑ Remove upper bolt securing starter motorto engine.

❑ Disconnect earth lead from bolt.

❑ Remove starter motor.

FITMENT

❑ Clean starter motor and mating faces ofstarter motor and flywheel housing.

❑ Fit and align starter motor to engine.

❑ Connect earth lead to starter motor upperbolt.

❑ Fit upper bolt securing star ter motor toengine and tighten it.

❑ Tighten lower bolts securing starter motorto engine.

❑ Connect battery cable to starter solenoid,fit nut and tighten it.

TESTING / CHECKINGSTART THE ENGINE

a) Engine not cranking at all

❑ Check Battery for connection

❑ Ensure Battery is in healthy condition

❑ Tighten starter motor terminals

❑ Check continuity as per circuit diagram

❑ Fix the connector properly

❑ Replace relay if found faulty

❑ Replace ignition switch if found faulty

❑ Replace starter motor.

b) Engine cranking but not starting

❑ Tighten starter motor terminals


❑ Replace starter motor

❑ Check & replace fuel pump.

c) Engine does not start / not starting incold conditions

❑ Check Battery for connection


❑ Tighten glow plug terminals

❑ Replace glow plug

❑ Replace glow plug temp. sensor

❑ Replace glow plug timer.

d) Engine does not STOP after ignition isswitched OFF

❑ Check wiring continuity

❑ Replace ignition switch if found faulty

❑ Check & replace fuel pump.

❑ Electr ical c ircui t diagram for star t ing,charging and engine stop solenoid may alsobe referred

NOTE :

Please contact local authorised serviceagency of M/s. Valeo for repairs on thisstarter motor.

Starter SolenoidStarter Motor

Fig. 35

32 EL

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Fig. 36

33

ELECTRICAL

8. SWITCHES, LAMPS AND OTHERCOMPONENTS :

A. STEERING LOCK CUM IGNITION SWITCH

Function

1. To lock the steering.

2. To start and stop the engine.

3. To switch on accessaries and other electricalsystem.

Location

It is located on the right side of the steeringcolumn below steering wheel.

Fig. 37 : Steering lock cum Ignition switch

LOCK ACC ON STARTPOSITION

KEY

TERMINAL

KEY IN SENCER

B

ACC

IG

ST

KEYMOVEMENT

L

L

L

F

F

F

F

F

F

F

F - FREE (LOCK BAR IN UNLOCK POSITION)

L - LOCK (LOCK BAR IN LOCK POSITION)

OUT IN

FORWARD

RETURN

34

ELECTRICAL

B. COMBINATION SWITCH RHD

Function

Right side lever of RHD operates turn signal, head lamp, low/high beam, parking & registration platelamps. Left side lever of RHD operates the wind shield washer of wiper.

Location

It is mounted on steering column.

Fig. 38 : Combi Switch RHD

35

ELECTRICAL

10

12

11

6

1

8

5

7

9

2

3

4

CO

NN

EC

TO

R T

ER

MIN

AL

NU

MB

ER

S

HORN

L.H. TURN

TURN FEED

R.H. TURN

BATTERY FEED

FLASHER

IGNITION FEED

SIDEHEAD (RELAY

MAIN BEAM

DIP BEAMLIGHTING FEED (RELAY)

FEED)

LEFT

TU

RN

TUR

N O

FF

RIG

HT

TUR

N

HA

ZAR

D O

FF

HA

ZAR

D O

N

LIG

HT

S O

FF

SID

E/T

AIL

ON

SID

E T

AIL

& H

EA

D

DIP

MA

IN

FLA

SH

SWITCH POSITIONSSWITCH CIRCUIT DETAILSDIRECTION INDICATOR HAZARD CIRCUIT

CO

NN

EC

TIO

N

DE

SC

RIP

TIO

N

4

9

7

8

3

6

1

CO

NN

EC

TO

R T

ER

MIN

AL

NU

MB

ER

S

TO WIPER CONTROL UNIT

SLOW MOTOR TERMINAL

FAST MOTOR TERMINAL

TO WASH PUMP

WIP

E O

FF

FLI

CK

WIP

E

INT.

WIP

E

VAR

IAB

LE D

ELA

Y

SLO

W W

IPE

FAS

T W

IPE

WA

SH

OFF

WA

SH

ON

SWITCH POSITIONSSWITCH CIRCUIT DETAILSWIPER CIRCUIT

CO

NN

EC

TIO

N D

ES

CR

IPT

ION

�IGNITION FEED


36

ELECTRICAL

C. COMBINATION SWITCH LHD

Function

Left side lever of LHD operates turn signals, head lamp, low/high beam, parking & registration platelamps. Right side lever of LHD operates the wind shield washer of wiper.

Fig. 39 : Combi Switch LHD

37

ELECTRICAL

10

12

11

6

1

8

5

7

9

2

3

4

CO

NN

EC

TO

R T

ER

MIN

AL

NU

MB

ER

S

HORN

L.H. TURN

TURN FEED

R.H. TURN

BATTERY FEED

FLASHER

IGNITION FEED

SIDEHEAD (RELAY

MAIN BEAM

DIP BEAMLIGHTING FEED (RELAY)

FEED)

LEFT

TU

RN

TUR

N O

FF

RIG

HT

TUR

N

HA

ZAR

D O

FF

HA

ZAR

D O

N

LIG

HT

S O

FF

SID

E/T

AIL

ON

SID

E T

AIL

& H

EA

D

DIP

MA

IN

FLA

SH

SWITCH POSITIONSSWITCH CIRCUIT DETAILSDIRECTION INDICATOR HAZARD CIRCUIT

CO

NN

EC

TIO

N D

ES

CR

IPT

ION

4

9

7

8

3

6

1

CO

NN

EC

TO

R T

ER

MIN

AL

NU

MB

ER

S


SLOW MOTOR TERMINAL

FAST MOTOR TERMINAL

TO WASH PUMP

WIP

E O

FF

FLI

CK

WIP

E

INT.

WIP

E

VAR

IAB

LE D

ELA

Y

SLO

W W

IPE

FAS

T W

IPE

WA

SH

OFF

WA

SH

ON

SWITCH POSITIONSSWITCH CIRCUIT DETAILSWIPER CIRCUIT

CO

NN

EC

TIO

N D

ES

CR

IPT

ION

�IGNITION FEED


38

ELECTRICAL

D) COMBI SWITCH:

FITMENT

❑ The Switch should be located on the steeringco lumn wi th Ant i Rotat ion pro ject ionengaged on the column slot.

❑ Hold the Switch down against the top of thecolumn with switch body symmetrical aboutY plane through column axis and tighten theclamping screw and check for firm fitmentby operating the stalks into all positions.

❑ Fix the nacelle and check for fouling andoperation of the stalks in the extremepositions. Rubber flaps (if fitted) should notcome out of the window in the nacelle andshould not obstruct the movement of thestalks.

❑ Apply contact grease on the horn contactpin and also smear the same to form a thinfilm on the contact face of the contact ringon the steering wheel.

❑ Care should be taken to engage thecancellation trigger projection into the slotson the steering wheel boss and check forself cancellation of RHS / LHS side indicatorfunction and also clearance between theswitch to & bottom of the spring boss andgap between contact ring and top of thecontact pin guide.

❑ Make the electrical connections.

REMOVAL

Please follow reverse procedure (relevant points)

TESTING / CHECKING

All functions are described component wise.

No serviceable parts inside. Replace combiswitch, iffound defective.

Please refer Electrical Circuits of Head Lamp ParkingLamp System, Front Wiper Washer System.

E) PIANO SWITCH:

Pl. refer assembly / removal of central consolebefore you proceed.

SNAP FIT TYPE

Press holding latch & push from the back, discon-nect wiring to remove. For fitment, make connec-tions & insert in the cavity from front.

TESTING / CHECKING

No serviceable parts inside. Replace the Switch ifnot functioning.

39

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L

Instrument cluster

RPM Meter :

Speedometer :

(4x4)(4x2)

km/hr

miles/hr

(optional)

4x4 Indicators

F) G

AU

GE

S &

IND

ICA

TOR

S - F

UN

CT

ION

AL

DE

TAIL

S :

H L4WD

km/h

1910 1420

Fig. 40

40

ELECTRICAL

1. Fuel gauge :Indicates the approximate level of fuel in tank.Fill up tank with recommended diesel fuel beforeneedle touches ‘Red’ mark on gauge.

2. Water temperature gaugeWhen needle touches red band it indicates engineoverheating.

3 & 6. Turn signal indicators (Green)

Turn signal lamps can be operated only whenignition is 'ON' and by using turn indicator switchon the combi switch.

Direction indicator arrow (LHS) & (RHS)on the instrument cluster flashes alongwithexternal indicator lights as selected.

4. SpeedometerIndicates vehicle speed in km/hr or miles/hr.

5. Odometer registers total distance covered by thevehicle in km or miles.

7. Engine RPM meter.It shows engine speed in revolutions per minute(RPM).

8. Battery charging indicator light. (Red)

This light should come ON when ignition is ‘ON’and should go off after the engine starts. If itremains ‘ON’ when engine is running, it indicatesbattery is not getting charged.

In such a case, avoid using electrical loads andget the problem attended at an authorisedworkshop.

9. High beam indicator (Blue)

It comes on when head lamp is operated in highbeam position.

10. Spare for Indicator

11. Rear fog lamp indicator

Indicator comes ‘ON’ when fog lamp is switchedon. Fog lamp operation is coupled with head lamps.

12. Trip counter setting knob

To reset it push the knob. Trip counter will showzero.

13. Trip Counter km. or miles

It indicates number of km or miles driven sincelast reset.

14. Spare for Indicator

15. Glow plug indicator light (Amber)

It glows when the ignition key is turned to position‘ON’ and after a few seconds depending on ambienttemperature the indicator light goes off indicatingthat the engine can be started.

If the glow plug indicator light does not go offautomatically, get the electrical system of yourvehicle checked.

16. 4WDH & 4WDL indicator (Green)(For 4x4 vehicle)

4WDH & 4WDL indicator lights glow up whenignition key is turned to position ‘ON’ and go offafter a few seconds. Either 4WDH or 4WDLindicator light glows continuously when four wheeldrive mode high or low respectively is selected.

17. Hand Brake + Brake fluid level indicator (Red)

It comes on when the brake fluid level in thecontainer is too low or when hand brake is on.

In case fluid level in container is low, get yourvehicle checked at authorised agency forleakages.

18. Oil pressure indicator light (Red)

It lights up when ignition key is turned to position‘ON’ and goes off as soon as the required oilpressure has developed after the engine hasstarted. If the light continues to glow when theengine is running, it indicates low oil level in engineoil sump, or a fault in the lubrication system.

Continued running of the engine when the oilpressure indicator light is on, may damage theengine.

19. Immobilizer - Anti theft security system (Red)(Optional)

This system disables starter motor circuit, ignitionsupply & fuel cutoff solenoid supply. The vehiclecan be started only if key fitted with correspondingtransponder is inserted in ignition switch.

20. Low Fuel Indicator (Amber/Orange)

It comes on when fuel level reaches 10 litres(approx.) in tank altering the user to fill fuel.

F) GAUGES & INDICATORS - FUNCTIONAL DETAILS :

41

ELECTRICAL

G) INSTRUMENT CLUSTER :

REMOVAL

1. Remove the bazel by unscrewing it.

2. Unscrew the cluster mounting screws frommounting bracket.

3. Remove speedocable by breaking the seal.

4. Remove electrical connector.

FITMENT

1. Insert the nyloc cage nuts in locating pointson dashboard.

2. Fit the mating connectors of W/H cabin inrespective cavities of Inst. Cluster.

3. Lay the speedocable and assemble at meterend and seal it by crimping the lead seal onthe wire lead.

4. While pulling the speedocable from bottom,insert the inst. cluster in the dash boardcutout.

5. Tighten the cluster mounting screws.

6. Ensure 2mm gap between lens surface andbazel

REMOVAL OF GAUGES:

1. Push the Assy. Front Dial by pulling the 7Latch notches.

2. Unscrew the Gauges from the back forremoval from the front.

REMOVAL OF BULBS :

1. Unwind the Lamp Holder.

2. Pull out the Bulb from the holder

3. Pull out the coloured cap (if fitted).

Note: Replace the specified bulb. Handle thecoloured cap gently.

FITMENT

Please follow reverse procedure.

42 EL

EC

TR

ICA

LEXPLODED VIEW INSTRUMENT CLUSTER

3

4

67

8

9

10

1

1 - Instrument Cluster2 - Front Dial3 - Speedometer4 - RPM Gauge5 - Fuel & Temp Guage6 - A/C Cut off & High Temp Module7 - Assemble Case8 - Bulb with cap9 - Buld holder10 - Capless Bulb

Fig. 41

43

ELECTRICAL

H. TROUBLE SHOOTING OF GAUGES & INSTRUMENTS :

Speedometer / Odometer

RPM Meter

Fuel Gauge

Temperature Gauge

Indicators

Speedometer / Odometernot working

4WDH / 4WDL indicatorsnot working

Fuel gauge not working

Fuel gauge needleflickeringLow Fuel level indicator notworking

Temperature gauge notworking

Temp. gauge needleflickering

Indicators not working

RMP Meter not working

❑ Ensure proper Speedocable engagement withSpeedometer

❑ Remove Speedocable & ensure that it is healthy bychecking manually.

❑ Replace speedocable if found faulty.❑ Replace Speedometer / Odometer if found faulty

Note : Use right Speedo ratio.

❑ Fix the connectors properly❑ Check the output voltage of alternator❑ If no output replace the alternator❑ Check continuity to meter❑ Replace RPM meter

Note : Ensure correct pulley ratio

❑ Replace the AC cutoff & high temp. module if foundfaulty.

❑ Replace the complete set of AC cutoff & high temp.module and gauge.Note: Ensure correct AC cutoff & high temp. moduleModel No.

❑ Fix the connector properly.❑ Check continuity from Fuel Tank Unit❑ Check resistance value of Fuel Tank Unit as shown in

the drawing.❑ Replace Fuel Tank Unit if found faulty.❑ Check Fuel Gauge by connecting external resistance

as per drawing.❑ Replace the fuel gauge if found faulty❑ Replace the fuel gauge.

❑ Fix the connector properly.❑ Replace Temperature transducer.❑ Replace temp. gauge.

❑ Fix the connector properly.❑ Fix the Bulb Holder properly❑ Replace the bulb.

❑ Replace the AC cutoff & high temp. module if foundfaulty.

❑ Replace the complete set of AC cutoff & high temp.module and gauge.Note : Ensure correct AC cutoff & high temp. moduleModel No.

Please refer Electrical Circuits of Instrument Cluster Indicators & Gauges, Hazard Warning & Direction Indicators& Flasher System.

Description Fault Testing / Checking

❑ Replace temp. gauge.

44

ELECTRICAL

I. GUAGES & INDICATORS - FITMENT,REMOVAL & TESTING :

FUEL GAUGE

FunctionFuel gauge indicates approximate level of fuelin the tank.

LocationIt is located on the instrument cluster

Checking fuel gauge

Connect the fuel gauge, tank unit and batteryas shown in fig. 43.

At the lowest position of the float the gaugeshould show E (empty) and at the highestposition F (full).

To check defective gauge, the tank unit inthe circuit should be alright and vise versa.

Note : Battery should be connected in correctpolarity.

FUEL TANK UNIT ASSEMBLY:Fitment❑ Remove Fuel Tank assembly.

❑ Release clip & disconnect fuel feed hose.

❑ Release clip & disconnect fuel return hose.

❑ Remove electrical connections.

❑ Remove 6 nuts securing Float Unit from thefuel tank.

❑ Remove seal from the Float Unit.

RemovalPlease follow reverse procedure

Testing / CheckingThe sender is a float operated rotary potentiometerwhich provides a variable resistance to ground for theoutput from the gauge. When the sender float is at itslowest point, indicating an empty fuel tank, theresistance to earth is at its lowest. The resistance issensed by the gauge which positions the needleaccordingly.

Use ohm-meter to confirm that the resistance of thefuel level sensor (Fuel Tank Unit) changes with thelevel of float position.

Fig. 43

CHECKING OF FUEL LEVEL GAUGE AND TANK UNIT

FUEL LEVELGAUGE

B TF

1/2

E

BATTERY

TANK UNIT

FULLPOSITION

HIGHESTPOSITION

LOWESTPOSITION

FLOAT

EMPTYPOSITION

Fig. 42

Fuel gaugeTemperature

gauge

Fuel

FUEL RESERVE INDICATOR(AMBER/ORANGE LED)

45

ELECTRICAL

J) HEAD LAMP / TAIL LAMP ASSY. :

Fitment (Head Lamp & Blinker)

❑ Locate the spring mounting bracket on theholes in the panel and tighten the bracketwith the fasteners.

❑ Insert the Head Lamp into the cutout for theHead Lamp and align the four mountinglocations.

❑ Tighten the lamp with the fasteners.

❑ Locate the Blinker in the locating panel.

❑ Insert the Blinker into the slots in the HeadLamp.

❑ Clamp the Blinker spring into the springlocating bracket.

❑ Connect the respective connectors for theHead Lamp and Blinker

❑ Check for the proper fitment of the Blinkerby ensuring proper engagement of the springand the Blinker locating lug.

Removal (Head Lamp & Blinker)

Please follow reverse procedure for fitment.

Head Lamp Assembly

Head Lamp Mounting Screws

Fig. 44

Fig. 45

Fig. 46

46

ELECTRICAL


Head Lamp Single HL RH not working � Tighten ground properly

� Fix Connector properly

� If fuse blown, check for any short circuit & thenreplace it

� Replace bulb

Both Lamps not working � Fix the fuse properly


� Fix the relay properly

� Replace relay

� Fix the connector properly

� Check for the function of combi switch

� Replace combi switch if found faulty

High Beam does not come ONwhen flash switch is operated





Low Beam not working � Fix the fuse properly


� Fix the relay properly

� Replace relay




Front Parking Lamps Single front parking lamp notworking

� Fix the connector properly� Fix the bulb properly� Replace bulb if blown� Tighten the grounding properly� Fix the fuse properly� If fuse blown, check for any short circuit & then

replace it� Check for the function of combi switch� Replace combi switch if found faulty

Both Lamps not working � Fix the connector properly� If fuse blown, check for any short circuit & then


K. TROUBLE SHOOTING CHART FOR LAMPS :

47

ELECTRICAL


� Fix the connector properly� Fix the bulb properly� Replace bulb if blown� Tighten the grounding properly� If fuse blown, check for any short circuit & then


Front Turn SignalLamps

Front right / left lamps notworking

Single reverse lamp not workingReverse Lamps

Both Lamps not working


replace it

� Fix the connector properly� Fix the bulb properly� Replace bulb if blown� Fix the fuse properly� If fuse blown, check for any short circuit & then

replace it� Replace the switch if found faulty

Parking Lamps Single parking lamp rear notworking

� Fix the bulb properly� Replace bulb if blown� Check for the function of combi switch� Replace combi switch if found faulty

Both lamps not working � Fix the connector properly� If fuse blown, check for any short circuit & then


Stop Lamp Single stop lamp not working � Fix the connector properly� Fix the bulb properly� Replace bulb if blown� Tighten the grounding properly� Fix the fuse properly� If fuse blown, check for any short circuit & then

replace it

� Tighten the grounding properly� Fix the fuse properly� If fuse blown, check for any short circuit & then

replace it

All lamps not working includingHigh Mounted Stop Lamp

48

ELECTRICAL


� Check brake switch, adjust if required� Fix the connector properly� Replace the switch if found faulty

Single Fog lamp not workingFog Lamps(If fitted)

Both Lamps not working

Side Repeater Lamps notworking

Registration Number Plate Lampnot working

Interior Lamps not working

Indicators not working withhazard warning switch isoperated

Side RepeaterLamps

Registration NumberPlate Lamp

Interior Lamps

Hazard Warning

� Fix the connector properly� Fix the bulb properly� Replace bulb if blown� Tighten the grounding properly

� Tighten the grounding properly� Fix the fuse properly� If fuse blown, check for any short circuit & then

replace it� Check relay & it’s base� Fix the connector properly� Replace relay� Fix the bulb properly� Replace bulb if blown




replace it


replace it� Check Hazard Warning switch� Fix the connector properly

� Replace the switch if found faulty

� Replace the Flasher

Please refer Electrical Circuits of Head Lamp Parking Lamp System, Interior Lights , Hazard Warning & DirectionIndicators & Flasher System.

49

ELECTRICAL

L) HORN:

REMOVAL

1. Horn is located on front bumper mountingbracket LH.

2. Removal can be from the Bottom Left Sideof the Vehicle.

3. Disconnect connection from horn.

4. Remove nut securing horn to mountingbracket.

5. Remove horn.

FITMENT

1. Position horn to mounting bracket andtighten nut .

2. Connect blade terminals to horn.

TESTING / CHECKING

a) Horn not working

q Tighten ground properly.

q Check fuse & continuity.

q Check relay & ensure it’s fitment in the base.

q Fix connectors properly.

q Check contacts of horn switch, adjust ifrequired.

q Replace the horn.

b) Horn Sound Deteriorated

q Adjust setting screw till clean & sharp soundis obtained.

Please refer Electrical Circuit of Twin Horns, Over-speed Warning Devices

Horn Securing Bolts

Setting Screw

Fig. 47

Fig. 48

50

ELECTRICAL

9) CONTROL UNITS :

A - BUZZER UNIT

FUNCTION

Its function is to generate the warning soundto aler t the dr iver about any abnormalcondition of the vehicle. It receives the inputfrom the chime unit.

Fig. 49 : Buzzer Unit

Buzzers given below have been provided :

1] Buzzer with timer for seat belt warning device.

2] Buzzer for head lamp / rear fog lamp on anddoor open conditions.

3] Buzzer for over speed warning device (optionalfitment).

Buzzers are located inside dash board behindinstrument cluster.

51

ELECTRICAL

TER NAME

H INPUT DRIVER DOOR SWITCH GND DOOR OPEN

J INPUT HEAD LAMP SWITCH VCC HEAD LAMP ON

D INPUT SEAT BELT SWITCH GND SEAT BELT NOT ATTACHED

C INPUT MAIN LINE SWITCH VCC KEY ''IN'' POSITION

A OUTPUT OUTPUT FROM UNIT VCC SEE PERF, CHECK TABLE

B INPUT MAIN LINE SWITCH (IGN) VCC KEY ''IN'' POSITION

E GROUND GROUND TO UNIT GND PERMANENT

TER TYPE DESCRIPTION ACTIVELEVEL

CONDITION

INPUT

KEY IGN. KEY IN DRIVER HEAD LAMP SEAT BELTPOSITION POSITION DOOR SW. SWITCH SWITCH

- - - - - - - - - ACTIVE ACTIVE - - - - - - - - - - - - - - - - - - ACTIVE

- - - - - - - - - INACTIVE ACTIVE ACTIVE - - - - - - - - - ACTIVE

ACTIVE ACTIVE INACTIVE - - - - - - - - - ACTIVE ACTIVE

PERFORMANCE CHECK

OUTPUT

Fig. 50 : Chime Unit

B. CHIME UNIT

It generates an output singal in some faultyconditions/usage & passes it to the buzzer unit. It ismounted inside dash board on driver side.

J

CHIME UNIT2702 5420 996012V 1W MAX.

SR. NO. YY XXXXXX

52

ELECTRICAL

C. FLASHER UNIT

Function

It provides blinking output to side indicatorsand hazard warning lamps.

Location

It is located below dashboard at driver side.

Connection details

Connection details are shown in fig. 53.

Checking flasher unit

a) Connect bulb to the flasher unit and batteryas shown in fig. 5. The bulb should blink at90 ± 30 cpm.

b) Disconnect one of 21 W bulbs. The remainingbulb should blink atleast 1.8 times of (a) or140 cpm whichever is greater.

Fig. 51 : Flasher unit

Fig. 53 : Circuit Diagram

MALE

Fig. 52 : Checking flasher unit

BATTERY

+

_

BULB

E

L

B

21W x 2

53

ELECTRICAL

D. GLOW PLUG TIMER

Function

It provides electrical supply to glow plugs forcontrolled period according to engine watertemperature.

Location

It is located in fuse / relay box inside theengine compartment.

Connection details

Fig. 54 : Electrical connection diagram

Fig. 55 : Glow plug timer

1) LAMP ON TIME AS PER TABLE

2) SAFETY SHUT OFF TIME AS PER TABLE

3) POST GLOW TIME AS PER TABLE

4) OVER VOLTAGE PROTECTION 14.5V ± 0.5

5) LAMP OUTPUT AND GLOW PLUG OUTPUT ARE SHORT CIRCUIT PROTECTED

TABLE

(0C) TEMPPRE GI.OW SAFETY SHUT OFF POST GI.OW

-30 30 40 200-20 23 33 200-10 17 27 2000 10 20 20010 8 18 20020 6 16 20030 4 14 12040 4 14 9050 4 14 6060 4 14 3070 4 14 1580 4 14 0

PERFORMANCE CHECK

TIME IN SECONDS

54

ELECTRICAL

Operating sequence

a. 'IG' contact 'ON' - indicator lamp burns uptoduration as decided by zone control lampextinguishes as shown in table 1 and 2.Glow plug continues to remain 'ON' evenafter lamp has extinguished. After controllamp extinguishes, engine should be startedby making 'ST' contact 'ON'. If engine ishot, 'ST' contact may be made 'ON' withoutwaiting for indicator lamp to extinguish.However, if 'ST' contact is not made 'on'.The glow plug supply is switched after aperiod as shown in the table 1 and 2. Thisis a safety feature.

b. 'ST' contact 'ON' - with 'IG ON', glow plugscontinue to remain 'ON' while engine iscranked.

c. 'ST' contact 'OFF' - the supply to glow plugsis cut off but then 'IG' contact will be 'ON'.In case second cranking is attemptedwithout 'IG' going 'OFF', the glow plugs willagain receive supply as long as startercontact is 'ON'.

d. Glow plug timer can be checked by simplemethod as shown in fig. 56.

Fig. 56 : Glow plug timer

12 V2

6 43

5 1

GLOW PLUG TIMER

Made in India

55

ELECTRICAL

TER NAME

H INPUT WATER LEVEL SENSE GND WATER LEVEL LOWJ INPUT COMBI SWITCH - WASH VCC SW. OPERATEDD INPUT COMBI SWITCH - INTERMITTENT VCC SW. OPERATEDC INPUT WIPER MOTOR PARK SW. A VCC/GND WIPER MOVING/WIPER PARKB SUPPLY WIPER MOTOR PARK SW.B VCC I/G POSITIONE GROUND GROUND TO UNIT GND PERMANENTA OUTPUT PARK TO COMBI SWITCH (53e) VCC - - - - - - - - -

TER TYPE DESCRIPTION ACTIVELEVEL

CONDITION

Fig. 57 : Front wiper Controller

E. FRONT WIPER CONTROLLER

Wiper controller is responsible for controlling thefunction of windscreen wiping/washing system.

Combiswitch lever operates windshield wiper &washer.

Wiper controller is located in dashboard behindinstrument cluster.

CONNECTION DETAILS

J

C

INFORMATION FITMENT OF WIPER CONTROLLER & EGR CONTROLLER

VIEW IN DIRECTION OF ARROW X

1) Fitment of Wiper and EGR Controller is shown for LHD Vehiclefor RHD Vehicle fitment will be mirror image of LHD

→

Wiper Controller

EGR Controller

DASHBOARD SUPPORT CROSS MEMBER

→CE

NT

RE

LIN

E O

F V

EH

ICLE

Fig. 58 : Wiper Controller & EGR Controller

VIEW FROM DRIVER SEAT

56

ELECTRICAL

F) EGR CONTROLLER

CONNECTION DETAILS

Terminal Terminal Description Active Condition Type Level

E Ground Ground to Unit GND Permanent

C Input Glow Plug Supply VCC Glow Plugs ON

B Input Throttle Switch VCC I/P till Throttle Pedal ReachesSet Limit

A Output O/P to EGR Solenoid GND As per Perf. Table

D Input Engine RPM from Alternator PULSES As per Perf. Table

J Input Air Conditioner Supply VCC Air Conditioner ON

H NC Not Used —- —-

Ignition Throttle Glow Plug Air Cond. Engine Rev. EGR ValveSupply Switch Supply (Note) ON Freq. (Hz)

—- Ter. B Ter. C Ter. J Ter. D Ter. A

0 0 X X X Float

1 0 X X X Float

1 1 1 X X OFF

1 1 0 0 X ON

1 1 0 1 < 334 OFF

1 1 0 1 > 334 ON

PERFORMANCE CHECK :Operation of EGR Valve

1 = VCC, 0 = GND / No Supply / Float, X = Don’t Care

Note : Engine Rev. Freq. Signal is 334 Hz +/- 5% [317 Hz to 350 Hz]

It takes input from engine rpm(alternator pulses), air conditioner‘ON’ signal and controls output toEGR soleniod.

EGR controller is mounted ondashboard behind instrument panel.

Fig. 59

57

ELECTRICAL

10) CENTRAL LOCKING SYSTEM

This vehicle has a single key for operating ignition,steering lock, glove box and doors.

All the doors have electrically operated central lockingsystem.

With central locking system all the doors can be lockedor unlocked from out side with the key. From inside,the doors can be locked or unlocked by operating theknob on the driver side door.

The system consists of master cum follower at driverside door and one follower each at codriver side door,rear doors RH/LH and a control module.

Preliminary checks

Carry out the following preliminary checks as per givenorder before starting the repairs.

● Check fuse. Replace blown fuse, if any.

● Check battery condition and state of charge.Recharge or replace battery as required.

● Check all related electrical connections includingearth connection for cleanliness and propergripping. Check specially the control unit earthconnection. Rectify as required.

● Operate driver's side door lock from inside andoutside and check functioning of central lockingsystem. Locate the faulty unit and carry outrepairs as given in subsequent paras.

● If the central locking system is found inoperativein total, check for the power supply at controlbox input end.

If this is OK, remove the control unit and checkfor proper functioning on the rig.

(Note : A simple test rig as per circuit diagramcan be made to check proper functioning ofvarious electrical aggregates of central lockingsystem.

Removal of Master cum follower unit /Follower unit

a) Take the door window glass in upper most position.

b) Remove door inner trim. Refer body group. Openout required portion of plastic membrane.

c) Disconnect electrical connectors of master cumfollower for driver side door.

* For master cum follower unit, the changeoverof sensor switch contacts takes place at 8 +0.5mm from position A while travelling in eitherdirection (from A to D or from D to A). Position Dindicates lock position.

CONTROLUNIT

TAILGATE(FOLLOWER UNIT)

For Crew cab For Crew cab

*

* Tailgate (Follower Unit) features are not provided with Telcoline singlecab & Crew cab

Fig. 60

Fig. 61

58

ELECTRICAL

d) Disconnect bell crank lever link for front door(inner lock link for rear door) from latch afterunlocking plastic clip. Disconnect solenoid linkof master cum follower from door latch afterunlocking the plastic clip.

e) Loosen mounting nuts and remove master cumfollower unit with mounting plate. Note the typeof zaster cum follower.

f) Follow the above procedure ('a'to'e') for removalof follower unit from co-driver side door, rear LHdoor and rear RH door. Note.the type of followerunit.

g) Follow the above procedure ('b'to'd') for removalof follower unit from tail gate. Loosen mountingscrews and remove the follower unit from tail gate.Inspection

● Cheek proper operation of door handle, lever, innerhandle and door lock. Rectify for any defect.

● Check the proper functioning of the replacedmaster cum follower unit / follower unit on the rig.Hold the output lever lightly to check that unit isexerting force. If not, replace with the workingunit.

Installation of Master cum follower unit /follower unit

a) For fitment of new master cum follower unit ondriver side door remove the mounting plate fromold master cum follower unit and fit on new mastercum follower unit. (New master cum follower unitand old one should be same type)

b) Fit master cum follower unit along with mountingplate on the door.

c) Assemble the solenoid link from master cumfollower to door latch. While fitment ensure thatknob and master cum follower lever is in samemode i.e., both are in unlock position or in lockposition. Lock the connecting link in position byplastic clip.

d) Assemble the bell crank lever link for front door(inner lock link for rear door) to door latch. Lockthe connecting link in position by plastic clip.

e) Connect electrical connectors of the master cumfollower to wiring harness.

f) Follow the above procedure ('a'to 'e') for installationof follower units on the co-driver side door, rearRH door and rear LH door.

g) Do not disturb the adjustment of door handle linkand door lock link. If disturbed readjust and ensureproper functioning of door handle and door lock.

h) Check and ensure proper functioning of the centrallocking system.

i) Fix plastic membrane, door inner trim. Refer bodygroup.

j) Check proper functioning of window winding.

59

ELECTRICAL

11 ELECTRONIC CONTROL UNIT (ECU)

TROUBLE SHOOTING OF 4X4 OPERATION

Self diagnosis of ECU:

ECU detects transfer case system malfunctionsand indicates through flashing indictor lights.Operator will be alerted of fault condition bycontinuous illumination of both 4WD HI and 4WDLO lights when ignition is On.

A service connector is provided to indicate faultcodes in binary. Connect one end to the pin holenumber 22 in ECU connector, and other end toignition switch. Flashing of indicator light will showdefective code (as illustrated in the table). Identifymalfunctioning part and replace it.

L1 L2 L3 Binary code Decimal equivalent Fault with

Off Off On 001 1 ECU Module

Off On Off 010 2 Shift Motor

Off On On 011 3 Synchronizer Clutch

On Off Off 100 4 Speed Sensor

On On Off 110 6 Selector switch

On On On 111 7 Motor Position Switch

If only one part is malfunctioning, indicator light willdisplay defective code three times continuously. Ifmore than two parts are malfunctioning, firstmalfunctioning part will be displayed three timesand then other malfunctioning par ts will bedisplayed.

After repair, clear the fault stored in memory.Ground the service connector and keep ignition ‘On’for five seconds continuously to erase defectivecode.

Note :

● Before replacing malfunctioning parts asindicated by system, check wires andconnectors for proper condition.

● Use only 12v 3-watt bulb for diagnosticpurpose.

60

ELECTRICAL

Diagnostic Table

Connect a service connector as described earlier.Turn ignition switch On. 4WD CHECK indicator willturn On for 0.6 seconds and turn Off for 3 seconds.Then it will display a defective code 3 timescontinuously.

Fig. 62 Defect code diagram

61

EL

EC

TR

ICA

L

Fig. 63 : C

onnection details of electronic control unit

PositionEncoder

ShiftMotor

Speedsensor

Speed RinSpeed

14 AWG Orange14 AWG Yellow18 AWG Yellow-White18 AWG Orange-White18 AWG Brown-White18 AWG White18 AWG Violet

A

AStatus display connector

Power connector

J1-14 Neutral safety switch

(Clutch depressed)

J1-19 + 12V IgnitionJ1-9/J1-10 + 12V BatteryJ1-3/J1-11 Ground

J1-8 4H DisplayJ1-15 4L DisplayJ1-22 Diagnostic display

J1-7 2H Switch

J1-13 4L Switch

Sector switch connector

B

B

J1-1/J1-2 Motor 2H-4H-4LJ1-16/J1-17 Motor 4L-4H-2HJ1-18 Common returnJ1-5 Pos. 1 motorJ1-12 Pos. 2 motorJ1-21 Pos. 3 motorJ1-20 Pos. 4 motor

J1-4 Clutch coil

Speed sensor coilconnectorMotor connector

J1-23 NoconnectionJ1-18 Speed RTN

Ignition

1 2 3 4 5 6 7 8

16 17 18 19 20 21 22 23

9 10 11 12 13 14 15

1 8

16 23AMP

Section A-A

Rear view of packard electric 121107517 - way motor connector

B

A

C

D

G

F

E

Section B-B

1. Motor control 2H-4H-4L2. Motor control 2H-4H-4L3. Ground4. Clutch coil5. Position 16. Speed sensor7. 2H switch8. 4H display

Rear view of packard electric12040977

3 way speed sensor / coilconnector

B

A

C

9. Battery in10. Battery in11. Ground12. Position 213. 4L switch14. Trans neutral15. 4L display16. Motor control 4L-4H-2H

17. Motor control 4L-4H-2H18. Ground (common ground)19. Ignition20. Position 421. Position 322. Diagnostic display23. No connection

4L4H

2H

ECU

A

GBFEDCA

CB

IGIG

Displaydiagnostic code

Jumper

CleardiagnosticJumper

62

ELECTRICAL

12) WINDSHIELD WIPING & WASHINGSYSTEM :

FITMENT

� Park the motor in parked position.

� Mount the wiper system assembly.

� Fix the arm / arms with blade / bladesincluding overtravel.

� Check the wiper / wipers for satisfactoryoperation and fouling with rubber beading inwet condition.

� Ensure no fouling takes place.

� Adjust the washer nozzle for the jet.

� Tighten the wiper arm when mounted on thewiper spindle.

� Make the electrical connections.

Front Wiper Front Wiper System not workingat all

� Tighten ground properly

� Fix the connectors properly

� Fix the fuse firmly in the base. If blown, checkfor short circuit and replace the fuse.

� Fix the controller in the base

� Replace the controller

� Replace front wiper motor

� Replace the switch

TESTING / CHECKING

Please refer Electrical Circuits of Front Wiper Washer System, Rear Wiper Washer System.

REMOVAL

Please follow reverse procedure (relevant points)


Front Windscreenwash

Front Wiper System does not workin all speeds

Front Windscreen washer notworking

� Connect the terminals properly

� Replace the wiper controller

� Fill tank with windscreen washer fluid

� Connect joints properly

� Tighten ground properly

� Fix the connectors properly

� Fix the fuse in the base properly. Replace ifblown

� Replace Pump

� Replace switch

63

ELECTRICAL

1. Wiper Motor W/Ris & Ther C/o RHD

1. Wiper Motor W/Ris & Ther C/o RHD

2. Assy Wiper Motor Mounting Bracket (RHD)

2. Assy Wiper Motor Mounting Bracket (LHD)

3. Hex Screw M6x20

4. Spring Washer B6

5. Assy Wiper Kit (RHD)

5. Assy Wiper Kit (LHD)

6. Assy Wheel Box

6. Assy Wheel Box

7. Assy Wheel Box

8. Assy Link Rod (i)

9. Assy Link Rod (ii)

9. Assy Link Rod LHD

10. Cover (Wiper Motor) RHD

10. Cover (Wiper Motor) LHD

11. SI Ch Screw M6x12

12. Bright Washer 6.4

13. Spring Washer B6

14. Assy Wiper Arm RH LHD

14. Assy Wiper Arm LH LHD

15. Assy Wiper Arm RH RHD

15. Assy Wiper Arm LH RHD

16. Wiper Blade Front

18. Gasket (for Wiper Motor Bracket)

18. Gasket (for Wiper Motor Bracket)

19. Kit Ele W/s Washer Mssl. (2.5 ltr)

20. Pump Assy

21. Tube

24. Tube 1800 mm

25. Clip

26. Nozzle Unit

27. Nozzle Adaptor

26. Nozzle Twin Jet

Fig. 64

64

ELECTRICAL

GENERAL DESCRIPTION

Wind Shield Wiper Motor Model 5SW60B seriesare of units designed to operate a link type Wipersystem to be used on Cars / Utility vehicles.

The Wiper Motor is a self switching two poledesign having permanent magnet field systemand provided with a gear box, housing a finalgear. The power developed by the motor istransmitted by worm teeth, provided on theArmature shaft, through the final gear system tothe rotary link. The rotary motion of the rotarylink is converted to reciprocating linear motion(to and fro motion) of the connecting rods whichin turn operates the wiping blades. The contactsin the cover plate ensure regenerative breakingto the Armature on completion of the wiping cyclewhen the switch turned ‘OFF’ and ensuresconsistent parking position of the Wiper armsand blades. The arms resting position is pre-setto suit the installation requirements.

PRECAUTIONS

ROUTINE MAINTENANCE

●●●●● Check for light run current, speed, directionof rotation and parking position of wipermotor to ensure correct assembly.

●●●●● Br ing the motor to park ing pos i t ionelectrically and then assemble the rotarylink in line with the noted marking on thegear box casting to ensure correct parkingposition.

●●●●● Ensure that the fasteners are tightened tothe recommended tightening torquevalues.

WIPING SYSTEM CHECK

●●●●● The wind screen wiper has a link typetransmission, check spindle assembly forany signs of seizure or rusting. Ensure thatthere is no looseness on the spindles andbetween the bearings and the links. Thelinkages must operate freely. If the bearingsare worn out replace with new linkages.

** Circuit cable resistance drop does notexceed 1.0 volt with motor current of 5.0Amps.

** Observe correct polarity while connectingmotor.

** Ensure recommended Arm / Blade sizes areused.

WIPER MOTOR ASSEMBLY CHECK

Motor terminal voltage. 13.5 Volts

Typical light 1.8 Amps (Normal Speed)Running current 2.8 Amps (High Speed)

65

ELECTRICAL

SPECIFICATIONS

WIRING DIAGRAM

1. TYPE 5SW60

2. RATED VOLTAGE 12V

3. TEST VOLTAGE 13.5 ± 0.2V

4. STARTING VOLTAGE 8V MAX

5. OPERATING VOLTAGE 10 ~ 15V

RANGE

6. TEST TEMPERATURE 25 ± 5OC

7. OPERATING TEMPERATURE

RANGE - 20OC — +90OC

8. INSULATION RESISTANCE 1M.ohm MIN

9.SPEED

2 Nm LOAD 45 ± 5 RPM

10. 14 Nm LOAD > 20 RPM

11. LOCK TORQUE (AT 0 RPM) > 25 NM

12. LOCK CURRENT 20 Amps.

13. NOISE - LOW SPEED / 50 dB (A) MAX /

HIGH SPEED 60 dB (A) MAX

Fig. 65

66

ELECTRICAL

EXPLODED VIEW

SPARE PARTS LIST

DESCRIPTIONSL.NO.

NO.OFF DESCRIPTION

SL.NO.

NO.OFF

1. NUT (ROTARY LINK) 1

2. ROTARY LINK 1

3. SCREW (MOUNTING PLATE) 3

4. RUBBER SHROUD 1

5. THRUST SCREW 1

6. NUT (THRUST SCREW) 1

7. GEAR BOX ASSEMBLY 1

8. BELLIVELI WASHER 1

9. FINAL GEAR ASSEMBLY 1

10. GASKET (GEAR BOX) 1

11. COVER & BRUSH PLATE ASSY. 1

12. SCREW (COVER PLATE) 3

13. SEALING RNIG 1

14. SCREW (BRUSH PLATE) 2

15. ARMATURE ASSEMBLY 1

16. BALL 2

17. SCREW (YOKE FIXING) 2

18. YOKE ASSEMBLY 1

19. TANDEM LINK & SPINDLE ASSY. 1

20. PRIMARY LINK & SPINDLE ASSY. 1

Fig. 66

67

ELECTRICAL

When dismantling the unit, carefully note downthe positions in which the various componentsare f i t ted in order to ensure their correctreplacement on re-assembly.

DISMANTLING

Fig. 67

Fig. 68

Fig. 69

●●●●● Remove the rubber grommet.

Ref. Fig.68

●●●●● Unscrew the cover plate f ixing screws(3 Nos).

Ref. Fig.69

68

ELECTRICAL

Fig. 70

Fig. 71

Fig. 72

●●●●● Remove the cover from the cover plate bodycasting.

Ref. Fig.70

●●●●● Remove the cover seal from the gear boxassembly.

Ref. Fig.71

●●●●● Remove the gear wheel.

Ref. Fig.72

69

ELECTRICAL

Fig. 73

Fig. 74

Fig. 75

●●●●● Remove the belliveli washer from the gearwheel shaft.

Ref. Fig.73

●●●●● Unscrew the yoke fixing screws (2 Nos).

Ref. Fig.74

●●●●● Hold the armature shaft and remove the yokeassembly to avoid brush damage.

Ref. Fig. 75

YOKE FIXING SCREW

70

ELECTRICAL

Fig. 76

Fig. 77

Fig. 78

●●●●● Please hold the 3 brushes by hand andremove the armature.

Ref. Fig. 76

BENCH INSPECTION

●●●●● Moulded gear check : Inspect the mouldedgear teeth for any damage or excess wear.

If so replace the gear assembly.

●●●●● Commutator check : Ensure that thecommutator surface is clean and smooth. Ifnot, clean with a smooth emery paper andwipe of the dust with petrol.

●●●●● Unscrew 2 nos brush plate fixing screw andseparate the brush plate assembly.

Ref. Fig. 77

●●●●● Armature Electrical Check :

Use 110 Volts AC mains 15W bulb with twoprobes. Connect as shown in figure. The bulbshould not glow if the bulb glows replace thearmature.

Ref. Fig. 78

71

ELECTRICAL

●●●●● Armature winding ground test :

Check the Armature on a growler tester forshort circuit and continuity of windings.

Ref. Fig.79

Fig. 80

Fig. 79

Fig. 81

LOW TEMPERA-TURE GREASEKRYOTEX EP2

PARKING POSITION CHECK

●●●●● Ensure proper positioning of the rotary linksafter every re-assembly. Align the rotary linkposition in line with the noted mark on thegear box casting.

●●●●● Ensure that the ball at the armature shaftend replaced in its groove with grease.

Smear “Turbo 41’ oil over armature shaft andfinal gear output shaft before assembly.

Prior to yoke f ixing, ensure contact ofbrushes with the commutator.

Ref. Fig.80

It is reverse order of dismantling procedure. Notethe following precautions.

RE-ASSEMBLY

●●●●● Smear low temperature grease KRYOTEX EP2over the armature shaft splines.

Ref. Fig.81

If not in position, motor will have excessivefrictional losses.

If the ball gets in between the magnets and thearmature it will result in motor locking conditionwhile energising, leading armature burning.

72

ELECTRICAL

Fig. 83

Fig. 84

Fig. 82

●●●●● Assemble armature on to the gear boxfollowed by brush carrier assembly, Ensurethat the contact of brushes on to thecommutator, before fixing yoke assembly onto the gear box.

Ref. Fig.82

●●●●● Belliveli washer in position. Ensure that theBelliveli Washer is replaced in proper positionon to the gear spindle as shown in

Ref. Fig.84

If it is assembled vice-versa, motor will havefrictional losses.

BELLIVELI WASHER

●●●●● Ensure that the gaskets are replacedproperly in its positions at the appropriatestage of re-assembly.

Ref. Fig.83

73

ELECTRICAL

Fig. 86

Fig. 87

Fig. 88

●●●●● Adjust the armature end float with the thrustscrew gap 0 to 0.05 mm.

Ref. Fig.86

●●●●● Do not mallet the yoke assembly. It mightresult in magnet breakage.

Ref. Fig. 88

●●●●● While assembling the yoke on to the gearbox match the notch on the yoke and gearbox for proper magnetic polarity.

Ref. Fig. 87

�

74

ELECTRICAL

TIGHTENING TORQUE

DESCRIPTION VALUE

Thrust screw nut 2.0 — 2.6 Nm

Yoke fixing screw 2.0 — 2.6 Nm

Brush Plate fixingscrew 0.8 — 0.9 Nm

Cover plate fixingscrew 2.0 — 2.5 Nm

Rotary link nut 12 to 14 Nm

TROUBLE SHOOTING

DIAGNOSTIC PROCEDURES

Following procedures assume that service technician has checked.

●●●●● Continuity of circuit harness wiring.

●●●●● That wiper-motor assembly-to-dash mounting hardware is tight.

●●●●● Circuit fuses

●●●●● That washer holes are clear, not kinked, disconnected or broken.

DEFECT REMEDY

a) Motor not working when 1) Check fuse.switched ‘ON’ 2) Check connections of both socket

and plug.

b) Motor does not park after 1) Cover plate defectiveswitching ‘OFF’ --change cover plate.

c) Jerky movement of the motor 1) Look for proper seating of brusheswhile running. on commutator.

2) Ensure Armature is free for defects.

d) Intermittant function 1) Ensure Wiper Motor Switchcontacts are OK.

BEFORE STARTING ENSURE THE BATTERY CONDITION

75

ELECTRICAL

13. ADDITIONAL FITMENTS :

DIGITAL CLOCK :

Digital clock is not offered as OE at present. Ifdigital clock is to be fitted, please reffer wiringdiagram 14B in page no. 91 for futher details.

HEADLAMP LEVELLING DEVICE :

A motorised head lamp levelling arrangement withthe setting knob is provided in central consolefor 4x4 vehicles & on dash board for 4x2vehicles.

This switch has 4 positions viz. 0,1,2,3. As andwhen required, depending on load, head lamplevelling is done by rotating the knob to selectone of the positions.

Levelling motor is an integral part of head lamp.Please refer wiring diagram 12 B in page no. 88for futher details.

REAR WINDSHIELD GLASS HEATING &DEMISTING DEVICE :

An illuminated switch is provided on dash boardto operate electrical demister of rear glass. Tooperate this device, keep ignition switch ON andswitch on demister switch. Lamp on switch willglow indicating that demister is ON.

Notice :

There no automatic control available to switchoff this function. Ensure to switch it OFF, whennot required.

Please refer wiring diagram 12A & 16 in pageno. 89 & 93 for futher details.

OVERSPEED WARNING DEVICE : (OPTIONAL)

When vehicle speed reaches beyond 120 kmph,buzzer starts beeping, warning driver about overspeed. When speed limit reduces below 120kmph, it switches off.

Buzzer for over speed warning device is fittedon dash board behind instrument cluster.

Please refer wiring diagram 17 B in page no. 94for futher details.

76

ELECTRICAL

14. GENERAL TROUBLESHOOTINGGUIDELINES

PRECAUTIONS

● Check fuses.

● Check the battery for damage, state of chargeand clean and tight connections.

● Check the alternator belt tension.

● Make sure connectors are clean and have noloose terminals.

Connection and disconnection of connectorsshould be done carefully.

● On the bracket mounted connector with duallocks, remove the connector from the bracketbefore disconnecting.

● When disconnecting locks, first press in theconnection tightly (to provide clearance to thelocking device), then operate the tab fully andremove the connector.

● When disconnecting a connector, pull it offfrom the mating connector by holding on bothconnectors.

● Never try to disconnect connectors by pullingon their wires.

● Place the plastic cover over the matingconnector after reconnecting. Also check thatthe cover is not distorted.

● Before connecting connectors check to seethat the terminals are in place and not bentor distorted.

● Check for loose retainer and rubber seals.

● Insert the connector tightly and make sure itis securely locked.

● Check all the wire harnesses are connected.

● There are two types of locking tab one thatyou have to push and the other you shouldnot touch when connecting the connector.Check the shape of the locking tab beforeconnecting.

● The locking tab having a taper end shouldnot be touched when connecting.

● Insert connectors fully until they will no longergo.

● The connectors must be aligned and engagedsecurely.

● Do not use wire harnesses with a loose wireor connector.

● Before connecting check each connectorcover for damage. Also make sure that thefemale connector is tight and not loosenedfrom the previous use.

● Secure wires and wire harness to the framewith their respective cabel ties at thedesignated locations.

Position the wiring in the bands so that onlythe insulated surfaces contact the wires orharnesses.

● After clamping, check each harness to becertain that it is not interfering with anymoving or sliding parts of the vehicle.

● Relocate corrugated tube suitably.

● Always keep a safe distance between wireharnesses and any heated parts.

● Do not bring wire harnesses in direct contactwith sharp edges or corners.

● Also avoid contact with the projected endsof bolts, screws and other fasteners.

● Route harnesses so that they are not pulledor slackened excessively.

● Protect wires and harnesses with a tape or atube if they are in contact with a sharp edgeor corner.

● Clean the attaching surface thoroughly if anadhesive is used. First wipe with solvent oralcohol if necessary.

● Seat grommets in their grooves properly.

● Do not damage the insulation when connectinga wire.

● Do not use wires or harnesses with a brokeninsulation.

Repair by wrapping with protective tape orreplace with new ones if necessary.

● After installing parts, make sure that wireharnesses are not pinched.

● After routing, check that the wire harnessesare not twisted or kinked.

● Wire harnesses should be routed so that theyare not pulled or slackened excessively,pinched or interfering with adjacent orsurrounding parts in all steering positions.

77

ELECTRICAL

● When using the Service Tester, follow themanufacturers instructions.

● Always insert the probe of the tester fromthe wire harness side.

● Make sure to use the probe with a taperedtip.

● Do not drop parts.

GUIDELINES

● Verify the Complaint.Turn on all the components in the problemcircuit to check the accuracy of the customercomplaint. Note the symptoms. Do not begindisassembly or testing until you havenarrowed down the problem area.

● Analyze the SchematicLook up the schematic for the problem circuit.Determine how the circuit is supposed to workby tracing the current paths from the powerfeed through the circuit components to ground.If several circuit fail at the same time, thefuse or ground is a likely cause.

Based on the symptoms and yourunderstanding of the circuit operation, identifyone or more possible causes of the problem.

● Isolate the Problem by Testing the Circuit.Make circuit tests to check the diagnosis youmade as above. Keep in mind that a logical,simple procedure is the key to efficienttroubleshooting. Test for the most likely causeof failure first. Try to make tests at pointsthat are easily accessible.

● Fix the ProblemsOnce the specific problem is identified, makethe repair. Be sure to use proper tools andsafe procedures.

● Make Sure the Circuit WorksTurn on all components in the repaired circuitin all modes to make sure you have fixedthe entire problem. If the problem was a blownfuse, be sure to test all of the circuits onthat fuse. Make sure no new problem turn upand the original problem does not recur.

15. WIRING DIAGRAMS :

Includes locations, Connection, Routing, Circuit Diagrams

1 INDEX AND SYMBOLS

2 WIRING HARNESS CONNECTORS LOCATION LAYOUT-RHD

3 WIRING HARNESS CONNECTORS LOCATION LAYOUT-RHD

4 WIRING HARNESS CONNECTORS LOCATION DETAIL VIEWS

5 CONNECTOR AND LOCATION ZONE CHART

6 CONNECTOR AND LOCATION ZONE CHART

7 FUSES & LOAD DISTRIBUTION DIAGRAM-F/B.NO.1.

8 FUSES & LOAD DISTRIBUTION DIAGRAM-F/B.NO.2.

9 STARTING,CHARGING & ENGINE STOP SOLENOID

10 HEAD LAMP AND PARKING LAMPS

11 BLINKER,TAIL,STOP,REV,READING & ENGINE LAMPS

12 REAR WIND SHIELD GLASS HEATING AND DEMISTING HEAD LAMP LEVELLING

13 INSTRUMENT CLUSTER

14 2-SPEED WIPER,WASHER & INTERMITTANT DIGITAL CLOCK

15 REAR FOG LAMP WITH WARNING BUZZER & ROOF LAMP

16 AIR CONDITIONING & HEATING DEMIST M/s.SUBROS

17 TWIN HORNS & ELECTICAL TAPPING OVER SPEED WARNING DEVICE

18 CENTRAL LOCKING WITH SINGLE MASTER

19 CHIME UNIT & SEAT BELT WITH BUZZER UNIT

INDEX

SR. NO. WIRING DIAGRAMS

78 EL

EC

TR

ICA

L

14.WIR

ING

DIA

GR

AM

79

EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

80 EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

81

EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

82 EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

83

EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

84 EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

85

EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

86 EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

87

EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

88 EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

89

EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

90 EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

91

EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

92 EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

93

EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

94 EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

95

EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

96 EL

EC

TR

ICA

L

WIR

ING

DIA

GR

AM

1

CABIN & LOAD BODY

CABIN &LOAD BODY

3

CABIN & LOAD BODY

Cabin assembly is normal control type all steelversion. Load body assembly is made of pressedsheet metal components.

Cab assembly is fitted with standard fitments likeseats/seat belts, inner/outer rear view mirrors, roof/map reading lamps, magazine pockets, arm restsgrab handles, ash tray/cigarette lighter,components of HVAC/heating system, roof linings,door padding, carpets, trims, fender extensions,bonnet release mechanism, console, shroud,nacelle etc.

This manual guides you for dismantling &assembly of these components.

New NVH package has been introduced in facelift version for better passenger comfort.

Please refer section on product improvements formodifications carried out on cabin & load body.

INTRODUCTION :

5

CABIN & LOAD BODY

CONTENTS



2. Removal / Installation of door padding 8

3. Removal / Installation of door 9

4. Removal / Installation of door outer handle / inner handle / latch 10

5. Removal / Installation of window glass/ window winding regulator 11

6. Removal / Installation of door mirror 12

7. Removal / Installation of bonnet 13

8. Removal / Installation of bonnet side panel 14

9. Removal / Installation of front bumper / rear corner bumper 15

10. Removal / Installation of seats 16

11. Removal / Installation of wind shield glass /rear window fixed glass 17

12. Removal / Installation of moulded roof lining 18

13. Removal / Installation of front seat belt 20

14. Removal / Installation of rear seat belt 21

15. Removal / Installation of console 4x4 23

16. Removal / Installation of console 4x2 24

17. Removal / Installation of dash board 25

18. Removal / Installation of shroud 27

19. Removal / Installation of nacelle 28

20. Removal / Installation of front grill 28

21. Removal / Installation of tail gate latch mechanism 29

22. Removal / Installation of tail gate 31

23. Removal / Installation of internal trims 32

24. Removal / Installation of bonnet release cable 34

25. Removal / Installation of fender extension 35

7

CABIN & LOAD BODY


TELCOLINE SINGLE CAB & CREW CAB

Type (single cab) : Normal control all steel cabin

Type (crew cab) : Normal control all steel crewcabin with two front and tworear doors.

Seats :

Option I : Reclining bucket seats withfoam laminated fabric, Frontand Rear adjustment and withadjustable head restraints.

Option II : Bench seat with foamlaminated fabric, Front andRear adjustment and withadjustable head restraints.

Note :

Option I is standard fitment for 4 x 4 vehicles.

Rear Row (Crew cab) : Non adjustable bench seat withfoam laminated fabric and withneck rests.

Seat Belt : 1) Three point mounting ELRSeat Belt for driver & co-Driver for Bucket Seatversion.

2) Three point mounting ELRSeat Belt for driver &outboard passenger andtwo point mounting lap beltfor middle passenger forBench Seat version.

Seat belt rear : Three point Mounting ELR Seatrow seat (crew cab) Belt for two outboard

passengers and two pointmounting lap belt for middlepassenger.

Wind Shield : Single piece laminated andtinted with darker built-in greentint band at top.

Rear Window : Single piece fixed glass.

Option : Tinted glass for all windows(with HVAC)

Mirrors : LH/RH Side External RearView Mirrors adjustable fromin side & Inner Antiglare RearView Mirror.

Ventilation :

Option I : Air conditioning with heatingand demisting.

Option II : Heating and demisting.

Radio cum CassettePlayer : Provision for fitment.

Digital Clock : Provision for fitment.

Load Body : Pick-up type with all steelnon-integral load body.

Hinged tail gate with 90o

opening and with lock handleat centre.

Provision for fixing canopy.

Recessed type tail lamp onload body.

Other Features : 1. Soft Feel Dash board /console

2. Moulded Roof Lining

3. Central Locking

4. Cab Guard on LoadBody

5. Provision for fixingcanopy on load body

6. Moulded Carpets

7. Sun Visors with PlasticMoulded Stem

8. Vanity mirror on sunvisor (Co-driver side)

9. Magazine Pockets

10. Ash Tray & CigaretteLighter

11. Rear under runprotection bumper

12. Cab guard on load body

13. Roof lamp at front (forcrew cab)

14. Pigmented fenders &rear corner bumpers

8

CABIN & LOAD BODY

56

2

4

3

1

Fig. 1

1. Cover padding with inner weather strip2. Door pull3. Inner handle cover4. Window regulator handle5. Magazine pocket6. Door padding

2. REMOVAL / INSTALLATION OFFRONT & REAR DOOR PADDING(Fig. 1)

REMOVAL

Note : Disconnect battery before doing repairwork on the body.

● Open the door.

● Pry out assembly cover padding from door shell.Cover padding is fitted with spring clips on doorshell. While taking out cover padding, care shouldbe taken to clear the pop-up knob.

● Remove mounting screws of door pull and removedoor pull.

● Remove mounting screw of inner handle coverand remove cover.

● Remove window regulator handle by pulling theregulator hand from padding.

● Remove magazine pocket two mounting screwsat bottom from door shell (for front door only).Magazine pocket will remain in position onpadding after removal of screws.

● Remove door padding alongwith magazine pocket(for front door only) from door shell, by separatingthe padding clips and door shell clips with thehelp of screw driver.

● Rear door padding removal procedure is sameas for front door, only magazine pocket is notthere in rear door padding.

INSTALLATION

● Replace door padding clips, if necessary.

● Locate door padding alongwith magazine pocket(for front door only) on door shell.

● Ensure that door padding clips are properlylocated in mounting holes.

● Press the door padding properly on door shell.

● Locate two holes at bottom of magazine pocket(for front door only) and tighten with screws.

● Fit the door pull using screw and tighten screws.

● Fit cover inner door handle with screw.

● Fit window regulator handle with plastic ring bypushing the handle on window regulator spindle.

● Fit cover padding by locating cover padding lugson to the spring clips on door shell and pushingthe cover padding on shell.

9

CABIN & LOAD BODY

3. REMOVAL / INSTALLATIONOF DOOR(Fig. 2)

REMOVAL

● Open the door

● Remove door padding. Refer 'Removal/installation of front/rear door padding'.

● Remove plastic sheet.

● Disconnect all connectors of electricalcomponents in side the door.

● Remove rubber grommet provided on the doorfor wiring harness.

● Take out wiring harness from door through thehole.

● Remove bonnet side panel for front door. Refer'Removal of bonnet side panel'.

● Push out hinge pin of door check.

● Support the door properly and removemounting screws of top and bottom hingeson the pillar.

● Remove door.

INSTALLATION

● Locate the door with the hinges on mountingholes at the pillar.

● Fit door top hinge with screws, spring washersand washers. Fit door bottom hinge withscrews, spring washers and washers. Ensureproper alignment of door and tighten mountingscrews.

● Align check strap hinge hole, with bracket onpillar and fit hinge pin using mallet.

● Insert wiring harness through grommet intothe hole provided for harness on door. Fitgrommet on door.

● Connect all electrical components' connectorsto wiring harness properly. Apply sealant ondoor inner panel and fix plastic sheet on itproperly.

● Fit bonnet side panel for front door.

● Fit door padding. Refer 'Removal/installationof front/rear door padding'.

Fig. 2

1. Top hinge2. Bottom hinge3. Location of hinge mounting

screws on piller4. Door check

1

3

3

2

4

10

CABIN & LOAD BODY

4. REMOVAL / INSTALLATION OFDOOR OUTER HANDLE / INNERHANDLE / LATCH(Fig. 3)

REMOVAL

● Remove door padding.

● Pull out required portion of plastic sheet.

● Disconnect links from outer handle.

● Remove mounting nuts and washers.

● Remove outer handle.

● Disconnect links from inner handle.

● Remove 2 mounting screws and 1 washer.

● Remove inner handle.

● Disconnect links from door latch.

● Remove 3 mounting screws of the latch.

● Remove latch.

Fig. 3 : Front door locking linkages

1. Door outer handle

2. Door outer handle link

3. Link (lock barrel to latch)

4. Inner handle

5. Door inner handle link

6. Door latch

7. Link (pop up knob)

8. Link (central locking)

4

5

3

7

1

6

2

INSTALLATION

● Locate outer handle on door panel. Installnuts and washers. Tighten nuts.

● Connect links to outer handle properly.

● Ensure handle functions properly.

● Locate inner handle on door panel.

● Install washers, screws and tighten screws.

● Locate latch on door.

● Install 3 screws and tighten screws.

● Connect links properly.

● Ensure proper functioning of latch.

● Fix the plastic sheet properly.

● Fit door padding.

8

11

CABIN & LOAD BODY

Fig. 4 : Front door window winding mechanism

5. REMOVAL / INSTALLATION OFWINDOW GLASS / WINDOWWINDING REGULATOR(Fig. 4)

REMOVAL

● Pull out the inner plastic cover of door mirror.

● Remove mirror by unscrewing mountingscrews.

● Unbent the lugs of outer end of outer weatherstrip. Remove outer weather strip.

● Remove cover door padding.

● Remove door padding.

● Pull out required portion of plastic sheet.

● Lower window glass using window regulatorhandle.

● Remove 2 window glass mounting screws,hold the handle in position and lift up theglass carefully.

● Remove mounting screws / nuts of windowregulator.

● Remove window winding regulator carefully.

INSTALLATION

● Locate window regulator in door in properposition.

● Fit window regulator mounting screws / nuts.

● Insert door glass in the window slot properly.

● Align mounting holes of door glass andregulator. Fit 2 screws and tighten screws.

● Roll up and down the glass and ensure thatglass is moving without binding. Ensure thatthere is no gap between glass and glass runmould, when glass is lifted up. Use windowregulator handle for rolling up and down theglass.

● Tighten regulator mounting nuts/screws.

● Fix plastic sheet properly.

● Fit door padding.

● Fit cover door padding.

1. Window glass2. Location of window glass mounting screws3. Window winding regulator4. Location of window winding regulator

mounting screws/nuts5. Window regulator handle

● Fit outer weather strip. Lock outer end bybending the lugs.

● Align mirror with mounting holes and tightenmounting screws. Refer removal / installationdoor mirror.

● Press fit inner snap cover properly.

12

CABIN & LOAD BODY

6. REMOVAL / INSTALLATION OFDOOR MIRROR

(Fig. 5 & Fig. 5a)

REMOVAL

● Pry out snap cover from inner plastic cover ofmirror mountings, from in side door.

For alternate design, pry out inner plastic cover(without additional snap cover) from in side door.

● Hold the mirror, remove mounting screws alongwith inner plastic cover & remove mirror.

For alternate design, hold the mirror, removemounting screws and remove mirror.

INSTALLATION

● Locate mirror properly on door gusset.

● Hold the mirror properly in such a way thatthree mounting points align with holesprovided on door gusset.

● Fit inner plastic cover from in side withmounting screws, washers and springwashers. Press inner snap cover.

For alternate design, put mounting screws,washers & spring washers on door gussetfrom in side. Press inner plastic cover.

Fig. 5a : Door mirror (For alternate design)

1. Mirror

2. Inner plastic cover

3. Mirror mounting holes

Fig. 5 : Door mirror (Standard design)

1. Mirror

2. Inner plastic cover

3. Mirror mounting holes

4. Inner snap cover

4

13

CABIN & LOAD BODY

Fig. 6

7. REMOVAL / INSTALLATION OFBONNET(Fig. 6)

REMOVAL

● Open the bonnet and support it with stay rod.

● Disconnect tube of wind screen washer fromnozzle.

● Support the bonnet properly and remove hingemounting nuts on bonnet from RH & LH sides.

● Remove bonnet.

INSTALLATION

● Locate the bonnet on hinges.

● Support the Bonnet with stay rod and hold itin proper position.

● Fit hex nuts, spring washers and washers forhinge mounting RH & LH to bonnet.

● Ensure correct position of bonnet by closingand opening bonnet.

● Tighten hinge mounting nuts.

● Connect tube of wind screen washer tonozzle.

1. Bonnet

2. Bonnet hinge

3. Mounting nuts

13

2

14

CABIN & LOAD BODY

Fig. 7 : Bonnet side panel

Fig. 8 : Bonnet side panel with fender extension

8. REMOVAL / INSTALLATION OFBONNET SIDE PANEL(Fig. 7 & 8)

REMOVAL

● Open the bonnet.

● Remove the side indicator at front corner byremoving mounting screws.

● Remove side indicator cover on bonnet sidepanel using screw driver. Remove mountingscrews and remove side indicator.

● Remove mud flap under wheel arch.

● Remove mounting screws of front fenderextension for 4x4 vehicles. Pull up andremove front fender extension.

● Remove the mounting screws of bonnet sidepanel and remove bonnet side panel.

INSTALLATION

● Mount bonnet side panel in position fit andtighten mounting screws.

● Mount front fender extension in position andfit mounting screws for 4x4 vehicles.

● Fit mud flap under wheel arch.

● Connect electrical connector and fit sideindicator at the front corner with mountingscrews and tighten screws.

● Connect electrical connector and fit sideindicator on bonnet side panel with mountingscrews and press indicator cover.

1. Bonnet side panel

2. Location of mounting screws - top

3. Location of mounting screws - rear bottom

4. Location of mounting screws - rear middle

5. Location of mounting screws - front

5

3

4

2 1

2

31 4

1. Bonnet side panel

2. Front fender extension

3. Side indicator at front corner

4. Side indicator on bonnet side panel

15

CABIN & LOAD BODY

9. REMOVAL / INSTALLATION OFFRONT BUMPER / REAR CORNERBUMPER(Fig. 9)

REMOVAL

Front Bumper

● Remove front skirt mounting screws andremove skirt.

● Remove bumper mounting screws from sidebracket RH & LH.

● Support front bumper properly and removemounting screws at centre of bumper andremove front bumper.

Rear Corner Bumper

● Hold rear corner bumper LH & remove nuts &reinforcements used for mounting corner bumperon side panel. Remove corner bumper LH.

● Apply same procedure for removal of cornerbumper RH.

Fig. 9

1. Front bumper

2. Location of mounting screws at side bracket

3. Location of mounting screws at number plate

4. Rear corner bumper

INSTALLATION

Front Bumper

● Align front bumper on centre support mountingholes & fit centre mounting screws.

● Align front bumper mounting holes on sidebracket and fit mounting screws.

● Align the skirt with mounting holes and fitmounting screws.

● Tighten mounting screws of front bumper,guard and front skirt.

Rear Corner Bumper

● Fit bumper rear side RH / LH with mountingscrews, spring washers, bright washers andtighten screws.

16

CABIN & LOAD BODY

10. REMOVAL / INSTALLATION OFSEATS(Fig. 10)

REMOVAL

● Remove seat mounting screws and removeseat.

INSTALLATION

● Locate the seat on fitment holes.

● Fit the seat using hex. screws, spr. washers,bright washers and tighten screws.

Fig. 10 : Seats

1. Bucket Seat2. Location of mounting screws for bucket seat3. Lever for seat adjustment (to & fro)4. Recliner handle knob5. Rear bench seat6. Location of mounting screws for rear bench seat7. Front bench seat8. Location of mounting screws for front bench seat9. Back rest recliner lever10. Lever for seat adjustment (to & fro)

17

CABIN & LOAD BODY

Fig. 11

11. REMOVAL / INSTALLATION OFWIND SHIELD GLASS / REARWINDOW FIXED GLASS(Fig. 11)

REMOVAL

● Wind shield glass / rear window fixed glassneeds to be replaced when glass is brokenor surrounding sheet metal area is badlydamaged.

● If glass is broken, remove the remaining partof damaged glass by braking it with mallet.

● Scrape the sealant between sheet metal &rubber mould.

● Remove rubber mould.

● If sheet metal portion is damaged and glassneeds to be removed, cut off the rubber mouldinner portion using knife and remove glassfrom in side.

41. Cab

2. Wind shield glass

3. Rubber mould

4. Rear window glass

5. Rubber mould 53

1

2

INSTALLATION

● Fit the rubber mould on wind shield glassproperly.

● Insert nylon rope in the rubber mould notch(to be fitted on window cut-out), such thatrope ends are coming at the bottom centreof the glass.

● Apply sealant between sheet metal & rubbermould.

● Align the glass mould on windows cut-outfrom out side. Pull out the wire rope from bothends such that mould notch will fit on windshield cut-out on body shell.

18

CABIN & LOAD BODY

12. REMOVAL OF MOULDED ROOFLINING

● Remove cab guard on load body.

● Disconnect all electrical connections.

● Remove rear glass (refer removal/installationof rear glass)

● Remove roof lamp front (for crew cab) andrear by unscrewing and disconnectingelectrical connections.

● Hold the roof lining properly and remove rearend fitment pins (for crew cab), middle fitmentpins (single cab) and driver side fitment pinsby prying out with help of screw driver.

● Unscrew grab handles, sunvisors and innerrear view mirror.

● Clear the edges of roof lining from in sidethe beading.

● Pull the roof lining downword and push throughrear glass opening and remove roof lining.

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Roof lining fitment pins (Driver side)

Roof lining fitment pins (Middle -Single cab)

Roof lining fitment pins (Rear-Crew cab)Cab guard on load body

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19

CABIN & LOAD BODY

INSTALLATION OF MOULDED ROOFLINING

● Insert the moulded roof lining through openingof rear glass.

● Hold roof lining to the roof.

● Position roof lining in such a way that rearlamp connector & front lamp connector (forcrew cab) passes through lamp fitment cutouts for fitment of lamps.

● Hold the lining and fit lamps with electricalconnectors.

● Fit front grab handles with screws on cabthrough roof lining holes.

● Fit the roof lining on cab with plastic pins.

Single cab : Driver side 2 pins, middle 4 pins.

Crew cab : Driver side 2 pins, rear 2 pins

● Fit rear grab handles with screws on cabthrough roof lining holes. (for crew cab)

● Fit sun visor LH/RH & inner rear view mirroron cab through the holes on roof lining.

● Fit front lamp with electrical connector (forcrew cab)

● Fit rear glass (see removal/installation of rearglass)

● Put the edges of roof lining in side the doorinner beading front and rear glass beading.

● Fit cab guard on load body.

● Connect the electrical connections.

Roof lamps & grab handles

Front lamp (Crew cab)

Grab handle screws

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20

CABIN & LOAD BODY

INSTALLATION OF FRONT SEAT BELT

● Fit top anchor screw of ELR seat belt onplastic trim of BC-Post.

● Assemble ELR unit of belt in side the cavityat bottom of BC-Post. Ensure that the dustentry prevention cap is fitted prior to assemblyof ELR unit.

● Fit seat belt guide bracket with two screwsafter placing outer part of seat belt, connectedwith ELR unit, within the guide bracket. Fitplastic cap on guide bracket by snap fit.

● Fit open end of seat belt anchor screw atBC-Post at bottom (for Crew Cab).

● Fit seat belt bottom anchor screw along withELR cover & fit ELR cover with two screws(for single cab).

● Fit BC-Post bottom lining putting the top flangeof lining under BC-Post plastic trim (for Crewcab).

● Fit seat belt buckle side stock to bracket onfloor (inboard side of veh.) with screw. Connetelectrical connector for driver side bucklestock.

13. REMOVAL OF FRONT SEAT BELT

● Remove the BC-Post bottom lining byunscrewing screws.

● Unscrew bottom anchor screw at B-C post(for crew cab)

● Remove B-C post ELR (Emergency lockingretractor) cover by unscrewing belt bottomanchorage & two screws at top of ELR cover(for single cab)

● Remove seat belt guide bracket plastic capby pulling the cap.

● Unscrew top anchor screw & hold seat belt.Remove ELR unit from BC post cavity &remove seat belt.

● Unscrew seat belt buckle side stock fromfloor bracket disconnecting electrical connector(for driver side buckle stock) & remove thestock.

B-C post bottom lining

Top anchor screw

Seat belt buckle side stock

21

CABIN & LOAD BODY

14. REMOVAL OF REAR SEAT BELT(CREW CAB)

● Open up seat cushion by putting rear end ofcushion towards upside. Front end of cushionis hinged to seat frame. Hold the cushionvertically.

● Unscrew LH buckle side stock of ELR belt &lap belt tongue side from floor LH bracket.Remove belt.

● Unscrew RH buckle side stock of ELR belt& lap belt buckle side stock from floor RHbracket. Remove belt.

● Close seat cushion by gentle push.

● Unscrew seat belt anchor screw at D-postbottom.

● Unscrew ELR cover / ELR belt screw.Remove ELR cover by prying out two plasticpins.

● Remove plastic cap on guide bracket bypulling the cap.

● Unscrew seat belt guide bracket & removebracket.

● Unscrew top anchor screw on D-post & holdthe belt. Remove ELR unit from D-post cavity& remove seat belt.

Seat belt anchor screw at D post bottom

Seat belt anchorage on B-C postBuckle side stock for rear seat

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CABIN & LOAD BODY

INSTALLATION OF REAR SEAT BELT(CREW CAB)

● Fit top anchor screw on D-post trim.

● Assemble ELR unit of belt in side the cavityat bottom of D-post. Ensure that dust entryprevention cap is fitted prior to assembly ofELR unit.

● Fit seat belt guide bracket with two screwsafter placing outer part of seat belt, connectedwith ELR unit, with in the guide bracket.

● Fit plastic cap on guide bracket, by snap fit.

● Assemble ELR cover at bottom & tighten withscrew & two plastic pins.

● Fit open end of seat belt anchor screw at D-post bottom.

● Open seat cushioning by pulling rear end ofcushion towards upside.

● Fit LH buckle side stock of ELR belt and lapbelt tongue side on floor LH bracket withscrew.

● Fit RH buckle side stock of ELR belt andlap belt buckle side stock on floor RH bracketwith screw.

● Close seat cushion by gentle push.

Top anchor screw on D-post

23

CABIN & LOAD BODY

15. REMOVAL OF CONSOLE (4X4VEHICLE)

● Unscrew three numbers of screws at eachside of LH/RH used for fit of console withfloor tunnel.

● Pry-out front console top fitment pins andrear end fitment pins.

● Remove gear shift lever bellow.

● Remove blower cover on co-driver side bythe side of front console by prying out twoplastic pins at top and unscrewing bottomfixation.

● Remove cigarette lighter, disconnectingelectrical connector.

● Pry out two nos. pins used for connectingfront & middle console.

● Now remove front console, middle consoleand rear console.

INSTALLATION OF CONSOLE (4X4VEHICLE)

● After fitment of floor carpet and fitment ofdash board, fit the console front by fixingtwo mountings at top with plastic pins onto the dash board.

● Fit middle console front edge below frontconsole and fix with two plastic pins atfront of middle console.

● Fit rear console with two screws (one LH& one RH) with floor tunnel.

● Fit front & middle console with two numbersof screws each side of LH/RH with floortunnel.

● Snap fit rear console cover.

● Assemble cigarette lighter with electricalconnector on console front.

● Assemble ash tray by gentle push onconsole front.

Console 4x4

Blower cover mounting pins

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Front console fitment pins

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24

CABIN & LOAD BODY

16. REMOVAL OF CONSOLE(4X2 VEHICLE)

● Remove rear cover by pry out.

● Unscrew console body rear two screws ontunnel top bracket.

● Unscrew console rear - front bottom screwsfrom LH & RH side.

● Unscrew the cover front screw, remove thesnap fitment by pull out. Remove coverfront.

● Remove console body rear.

● Unscrew console body front two screws ontop of tunnel at front side.

● Unscrew console body front two screws atrear side on tunnel bracket.

● Unscrew one screw each side of LH & RHfrom console body front, at front bottom.

● Remove the console body front.

INSTALLATION OF CONSOLE (4X2VEHICLE)

● After fitment of floor carpet & dash boardfit the console body front on tunnel top withtwo screws.

● Fit console body front with one screw eachside of LH & RH at front bottom, withtunnel side bracket.

● Fit console body front with two screws atrear end, with tunnel bracket.

● Fit console body on body front by snap fit& with one screw.

● Assemble console at rear of tunnel. Fitalongwith console body front flange on tothe tunnel side bracket by one screw eachside of LH & RH, at front bottom.

● Fit console body rear with two screws onto the tunnel top bracket at rear.

● Snap fit rear cover at rear end of body rear.

Console

Console

25

CABIN & LOAD BODY

i

17. REMOVAL OF DASH BOARD

● Remove battery

● Unscrew two cut out covers near centrebonnet hinges on support panel (Enginehouse side)

● Unscrew the nuts used for fitment of dashboard on fire wall, through support panelcut outs.

● Remove steering wheel.

● Remove shroud - refer removal of shroudprocedure (page 29).

● Remove nacelle bottom, front & rear - referremoval of nacelle procedure (page 30).

● Remove instrument cluster.

● Remove combi switch.

● Remove the handbrake on dash board forbench seat version.

● Unscrew the bottom mounting screws ofdash board with dash board cross member.

● For 4x2 vehicle remove control knob caps& cover from dash board afterdisconnecting push-pull cables.

● Remove map reading lamp & disconnectelectrical connector.

● Before removing the dash board ensure thatall electrical connectors are disconnected.

● Lift the front edge of dash board from underthe wind shield glass mould.

● Remove console front - refer removal ofconsole (page 25 & 31).

● Hold dash board & pull it towards rear toclear the dash board from top centre locatoron fire wall.

● Pull dash board rear wards & remove it.

Dash board

Nacelle mounting screws

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Nacelle front, rear & bottom

26

CABIN & LOAD BODY

iii

INSTALLATION OF DASH BOARD

● Assemble dash board front top centre onlocator pin of fire wall.

● Ensure that front edge of dash board isplaced under wind shield glass mould.

● Fit dash board with two nuts from enginehouse side, through the cut outs of supportpanel, near centre bonnet hinges & replacecut out covers.

● Fit instrument cluster on dash board.

● Fit combi-switch.

● Fit nacelle front / rear / bottom oversteering column - refer nacelle installation(page 30).

● Fit shroud - refer shroud installation (page29).

● Fit bottom mountings of dash board withdash board cross member with screws.

● For 4x2 vehicle f i t the control cover,connecting the push pull cables. Fit thecontrol knob caps.

● Fit map reading lamp & electrical connector.

● Ensure that all electrical connectors areconnected.

● Refit front console in posit ion - referconsole installation (page 26 & 31).

● Assemble battery in posit ion withconnections.

Dash board

Control panel (HVAC) & air ducts

27

CABIN & LOAD BODY

18. REMOVAL OF SHROUD ON DASHBOARD

● Disconnect all electrical connections.

● Unscrew two screws at bottom of shroudon dash board.

● Remove two screws caps on top of shroudby pry out.

● Unscrew two screws below screw caps.

● Remove switches on shroud & disconnectconnectors.

● Remove shroud.

INSTALLATION OF SHROUD ONDASH BOARD

● Place the shroud on dash board.

● Fit the shroud with two screws at bottom,on dash board.

● Fit the shroud with two screws at top ondash board.

● Fit two screw caps by snap fit to covertop mounting.

● Fit electrical connectors for switches onshroud & fit switches.

Shroud

28

CABIN & LOAD BODY

19. REMOVAL OF NACELLE

● Unscrew four screws for fitment of nacellebottom & remove nacelle bottom.

● Unscrew five screws for fitment of nacellefront & rear with steering column.

● Separate nacelle front & rear by pry out &remove.

INSTALLATION OF NACELLE

● Assemble nacelle front & rear above &below the steering column covering thecombi switch.

● Fit nacelle front & rear with five screws.

● Fit nacelle bottom with four screws on dashboard.

20. REMOVAL OF FRONT GRILL

● Unscrew four screws & washers frombottom of grill mounting bracket.

● Unscrew two screws & washers from topof grill mounting bracket.

● Remove assembly front grill.

INSTALLATION OF FRONT GRILL

● Fit four numbers of screw gromments onbottom brackets of grill mounting.

● Fit two numbers of screw grommets on topbrackets of grill mounting.

● Place assembly front gri l l on to themounting brackets & fit with screws /washers.

Nacelle

Front Grill

29

CABIN & LOAD BODY

21. REMOVAL OF TAIL GATE LATCHMECHANISM

● Remove tail gate handle by unscrewing twomounting screws from tail gate centre latchhandle lever.

● Remove cover by unscrewing two mountingscrews from tail gate outer panel.

● Disconnect pull rod hook nylon clip endfrom centre latch levers at LH & RH sidesafter loosening the threaded adjustment ofpull rod.

● Remove centre latch by unscrewing threemounting screws on tail gate inner panel.

● Unscrew bottom mounting screw of plunger/striking strap/rope fitment at LH & RH sideon tail gate.

● Unscrew assembly rope mounting screw atLH & RH from load body & removeassembly rope LH & RH.

● Unscrew top mounting screw of plunger/striking strap fitment at LH & RH on tailgate.

● Remove striking strap, assembly plungercomplete with pull rod assembly by pullingthe assembly from out side at LH & RH.

● Seperate out assembly pull rod fromassembly plunger by removing the bent endof pull rod from plunger slot.

Tail gate & rear body under runner

Tail gate handle screws

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Tail gate rope

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30

CABIN & LOAD BODY

INSTALLATION OF TAIL GATE LATCHMECHANISM

● Assemble the assembly pull rod withassembly plunger complete by inserting bentend of pull rod in the slot of plunger.Assemble pull rod hook to the other endof assembly pull rod. Fit nylon clip to pullrod hook end. Apply grease on plunger forfree movement while assembling.

● Inser t pull rod end of above assemblythrough tail gate shell side top cut out toin side the tail gate shell & put the plungerhousing flange & mounting strap out sidethe shell.

● Assemble striking strap on mounting strap& fit the assembly with tail gate with onescrew on each side of LH & RH at top.

● At bottom put one spacer & assembly ropeon striking strap & fit the assembly on tailgate with one screw on each side of LH &RH. Assembly rope LH & RH are to befitted at LH & RH side respectively. Otherend of rope is to be fitted on load bodywith a screw along with a spacer.

● Position the assembly centre latch on tailgate inner panel through the cut outprovided on tail gate outer panel. Fit thelatch with three screws from out side theinner panel. Apply grease on levers of latchfor free movement of levers.

● After adjustment of pull rod length, withthreaded adjustment, connect the pull rodhook nylon clip end to centre latch leversfrom LH & RH sides.

● Assemble cover in side the cut out of tailgate outer panel & fit with two screws.

● Fit the handle on centre latch handle leverwith two screws.

31

CABIN & LOAD BODY

22. REMOVAL OF LOAD BODY TAILGATE

● Open the tail gate resting on two side ropes.

● Unscrew hinge mounting (tail gate side)screws three numbers each side of LH &RH.

● Support the tail gate properly & unscrewthe rope mounting (tail gate side) screw onenumber each side of LH & RH along withspacer.

● Remove tail gate.

INSTALLATION OF LOAD BODY TAILGATE

● Position the tail gate (fitted with latches,pull rod & plungers) in such a way that thehinge leaf & LH / RH (tail gate side) goesin side the tail gate hinge cavity. (Hinge isalready fitted on load body side).

● Support the tail gate suitably & fit the hingeleaf (tail gate side) LH & RH with threenumber of screws at each side.

● Fit the LH/RH assembly rope end (tail gateside) - refer installation of latch, pull rod,plunger (Other end of assembly rope LH &RH is already fitted on load body side.

● While fitment of tail gate, crease line of tailgate should match with crease line of loadbody & gap between load body & tail gateshould be equal at LH & RH side.

Tail gate hinge

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32

CABIN & LOAD BODY

23. REMOVAL OF INTERNAL TRIMS

A - POST TRIM

● Remove front door inner sealing.

● Remove three plastic pins by pry out.

● Clear top end of trim from below roof lining.

● Pull the trim slowly towards rear side,clearing the dash board & remove A-posttrim.

B-C - POST TRIM (CREW CAB)

● Remove front & rear door sealing.

● Unscrew seat belt mounting top anchorage.

● Unscrew seat belt guide bracket.

● Remove plastic pins by pry out.

● Remove B-C post trim by clearing the trimfrom below roof lining.

B-C - POST TRIM (SINGLE CAB)

● Remove inner cover at top of B-C post bypry out.

● Remove door sealing.

● Unscrew seat belt mounting top anchorage.


● Remove plastic pins by pry out.

● Remove rear wall trim plastic pins by pryout.

● Remove rear wall trim by clearing the topflange from below rear glass sealing mould& bottom flange from below rear wallpadding.

● Remove rear wall padding.

● Remove B-C post trim by clearing the trimfrom below roof lining.

D - POST TRIM (CREW CAB)

● Remove inner cover at top of D-post by pryout.

● Unscrew seat belt top anchorage.


● Unscrew ELR cover anchorage.

● Remove two pins for fitment of ELR coverby pry out.

● Remove rear seat.

● Remove rear wall trim (below rear glass)plastic pins by pry out.

● Remove rear wall trim by clearing the topflange from below the rear glass sealingmould & bottom flange from below the rearwall padding.

● Remove rear wall padding.

● Remove D-post trim by clearing trim frombelow the roof lining.

B-C post trim

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33

CABIN & LOAD BODY

INSTALLATION OF INTERNAL TRIMS

● Assemble A-post trim on A-post mountinglocation & fit with three plastic pins.

● For Crew Cab - Assemble B-C post trimon B-C post mounting location & fit withthree plastic pins & one button.

● For Single Cab - Assemble B-C post trimon B-C post mounting location & fit twoplastic pins.

● Fit rear wall trim (below rear glass) onmounting location with four plastic pins,pulling the ends of trim over B-C post trim.Rear wall trim bottom flange is to be putunder rear wall padding.

● Assemble door inner sealing. Front edge ofB-C post trim is to be put in side sealingflange.

● Rear edge of B-C post trim & rear wall trimtop flange are to be put in side rear glasssealing mould.

● Assemble rear edge of A-post (for SingleCab & Crew Cab) in side door sealing flange.

● For Crew Cab - Assemble D-post trim onD-post mounting location & fit with twoplastic pins.

● Fit rear wall trim (below rear glass) onmounting location with four plastic pins,pulling the ends of trim over D-post trim.

● Rear wall trim bottom flange is to be putunder rear wall padding. Assemble rear doorinner sealing. Front edge of D-post trimneeds to be put in side rear door sealingflange. Rear edge of D-post trim & rearwall trim top flange are to be assembled inside rear glass sealing mould.

● Top ends of A, B-C & D post are to beassembled below roof lining.

A post trim

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34

CABIN & LOAD BODY

24. REMOVAL OF BONNETRELEASE CABLE

● Remove split pin, washer used for fitmentof bonnet release cable fork end withcentre bonnet mounting bracket bottomassembly.

● Loosen two nuts for fitment of release cablewith centre bonnet mounting bracket bottomflange.

● Remove fork end of cable from bottombracket assembly.

● Loosen screw of clamp for holding releasecable on side bonnet inner panel & removethe cable from clamp.

● Unscrew release cable bracket assemblyfrom the side of body.

● Remove rubber gromment from hole of firewall.

● Pull release cable clearing the path throughradiator mounting bracket & engine house.Remove the cable from in side cab.

FITMENT OF BONNET RELEASECABLE

● From in side the cab assemble bonnetrelease cable fork end, through the hole offire wall, towards engine house.

● Fit the bracket of release cable to the sideof body with screws at RH side for RHDvehicle & LH side for LHD vehicle.

● Hold release cable at engine house withclamp & screw, on side bonnet inner panel.

● Pass release cable through the cavity ofradiator mounting bracket at top.

● Tighten two nuts of bonnet release cablewith centre bonnet mounting bracket bottomflange (below tie member), with one nut ateach side of flange.

● Tighten fork end of bonnet release cablewith washer, screw & split pins to centrebonnet mounting bracket, bottom assembly.

Bonnet release cable

35

CABIN & LOAD BODY

25. REMOVAL OF FRONT FENDEREXTENSION

● Unscrew bottom mounting screws of fenderextension.

● Hold fender extension & unscrew fenderextension fitment bracket from side panelouter & remove the brackt.

● Lift fender extension upward to remove itfrom clips.

Note :

Process of removal of load body fenderextension is same as above.

INSTALLATION OF FRONT FENDEREXTENSION

● Fit eight nos. of clips fender extension onthe cut out of bonnet side panel outer.

● Fit front mud flap with top four nos. ofscrews & washers.

● Fit fender extension fitment bracket (4 nos.)on side panel outer in loose condition withscrews & washers. One bracket fitment isthrough mud flap bottom mounting.

● Fit fender extension top flange in clip fenderextension fitted on side panel outer.

● Fit bottom mountings of fender extensionwith screws, washers & nuts with fenderextension bracket. After positioning fenderextension & bracket in correct location,tighten all screws.

● Fit fender extension beading with adhesive.Through out the beading length along theperiphery of fender extension beforetightening screws.

Note :

Process of fitment of load body fenderextension is same as above. Only numberof clips for fender extension & brackets aredifferent.

Front fender extension

Rear fender extension & rear corner bumper

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1

VENTILATION SYSTEM

HEATING, VENTILATION &AIRCONDITIONING

3

VENTILATION SYSTEM

INTRODUCTION :

Two types of ventilation systems are available asoption in Tata TL.

1] Heating and Airconditioning (HVAC)

2] Heating

In heating and airconditioning arrangement controlson central console can be adjusted to mix heatingand cooling to get desired effect.

In heating arrangement temperature of air iscontrolled by adjusting flow of engine coolantthrough water valve and blower speed.

In both arrangements provision has been made fordemisting windshield glass and door glasses.

This section deals with heating and airconditionining (HVAC) system.

5

VENTILATION SYSTEM

CONTENTS :


1. Specifications & Schematic layout of HVAC 7

2. Basic components of AC system 8

3. HVAC controls panel 11

4. Magnetic clutch 12

5. Vacuum switching valve 13

6. Dual Pressure switch & Thermo amplifier 14

7. Removal and fitment of A/C components 15

8. Components of Evaporator assembly 16

9. Removal & Fitment of blower assembly and blower resistor 17

10. Components of blower motor assembly 18

11. Removal & fitment of evaporator assembly / Themister / Expansion valve 19

12. Removal & fitment of condenser assembly & compressor clutch 20

13. Removal & fitment of receiver dryer and refrigerant pipe lines 21

14. Safety features and specification/quantity of refrigerant & compressor oil 22

15. Do's and Don'ts 23

16. A/C check up points 24

17. Refrigerant (R134a) 25

18. Compressor oil 26

19. Service tools and gas leak detector 27

20. AC inspection 28

21. AC charging 30


23. AC performance check-up procedure 39

7

VENTILATION SYSTEM

SPECIFICATIONS:

PARAMETER VALUE

COOLING CAPACITY 3080 ±310 kcal/hr

at 280 ±28 m3/hr

AIR FLOW AMOUNT 400 m3/hr

RATED VOLTAGE 13.5 V

ELECTRIC CONSUMPTION (Total) 376 W

BLOWER MOTOR 216 ±21w

MAGNETIC CLUTCH 40 W

COND. FAN MOTOR 120 W

EVAPORATOR 311 x 185 x 85 mm

CONDENSER (SERPENTINE) 330 x 490 x 22 mm

COMPRESSOR TYPE 10 P13 (133.6 CC/rev.)

REFRIGERANT TYPE R 134a

QUANTITY - 670 ± 20 grams

LUBRICATING OIL DENSOIL - ND8

Quantity - 80 ± 20 c.c.

VENTILATION SYSTEM WITH HEATING AND AIRCONDITIONING

CondenserAir

Flow

8

VENTILATION SYSTEM

Fig. 1

1 ASSY INT UNIT W/AC BLOWER2 COMP ASSY W/MAG CLUTCH3 CONDENSER ASSY4 TANK RECIEVER5 FOSE SUCTION6 HOSE DISCHARGE7 TUBE LIQUID( COND. OUT)8 TUBE LIQUID ( R/D IN )9 TUBE LIQUID ( R/D OUT)10 BKT COMP MOUNTING11 HOLDER RECIEVER12 VACCUM SWITCHING VALVE13 CLAMP HOSE SUCTION14 GROMMET

PARTS FOR AIRCONDITIONING SYSTEM :

15 GROMMET16 ACTUATOR SET IDEAL UP WITH BKT17 HARNESS S/A WIRING A/C18 HARNESS S/A WIRING A/C19 HOSE DRAIN W/GROMMET20 CLAMP PIPING ( R/D INLET)21 HOSE VACCUM22 ASSY AMP W/BRACKET23 ASSY BKT W/V. RESISTER24 CLAMP PIPING25 ASSY AMPLIFIER WITH VARIABLE

RESISTOR COMPLETE26 TUBE AND ACC ASSY27 CLAMP PIPING

S.No. Part Name S.No. Part Name

9

VENTILATION SYSTEM

AIR CONDITIONING SYSTEM – FULL AIR MIX TYPE

BASIC COMPONENTS

The circuit consists of basic components givenbelow. Refer Fig. No.1

● A/C compressor

● Condenser

● Receiver dryer

● Expansion Valve

● Evaporator

● Pipes and Hoses

● A/C controls

Compressor :

10 P(A) type compressor is used in this system.

Compressor draws of gaseous refrigerant fromevaporator & compresses it. This cause refrigerantgas temperature & pressure to raise rapidly.

It is critical that only gas be drawn into thecompressor. If liquid enters, it will causehydrostatic lock in compressor and stall it.Refrigerant drawn in compressor is compressed toover 14.1 kg/cm2, which causes it to get very hot.

A safety valve has been provided in compressor tosafe guard it from high pressure.

If discharge pressure in the system increasesbeyond 35 to 42.2 kg/cm2, safety valve will openand will release high pressure gas from thesystem.

When pressure drops down to 28 kg/cm2, safetyvalve will close with the help of spring force andwill stop leakage of refrigerant.

Condenser :

Condeser, through heated refrigerant gas gives offheat to engine cooling air. Refrigerant gas cools offand once again becomes liquid.

Condenser is mounted in front of radiator. Itchanges high temperature gas into liquid under highpressure. When operating in normal conditions, inletof condenser is full of hot gas and outlet is full ofhot liquid.

Condenser fan cools refrigerant inside condensercore.

Assy. Int unit W/AC blower

Compressor

Condenser

10

VENTILATION SYSTEM

Receiver dryer

Receiver dryer removes any traces of moistureand filters out dirt in the system. It also servesas a reservoir for excessive refrigerant.

This component acts as a storage device forliquid refrigerant. It also contains a filter anddesiccant to absorb moisture from l iquidrefrigerant.

A sight glass has been provided to check theamount of refrigerant.

Expansion Valve

This valve controls flow of refrigerant intoevaporator cores, causing drop in pressure andconsequently drop in temperature. It is controlledby a temperature sensor at evaporator outlet. Ifoutlet temperature is too high, it means notenough refrigerant is flowing into the evaporatorand poor passenger cooling will result.

If outlet temperature is very cold, it means toomuch refrigerant is flowing and evaporator finswill probably load up with ice. In either case,temperature sensor opens or closes expansionvalve opening to achieve correct flow rate andevaporator outlet temperature.

Evaporator

Evaporator in which the released refrigerantexpands and flow through evaporator tubes. Thisremoves heat from air blowing across the fins &tubes, and evaporates, causing temperatureinside cabin gradually to be lowered.

The last component in the cycle, and where wefinally get around to cooling air. As the foggymist of refrigerant enters, air passing over theevaporator fins gives up its heat to evaporatingrefrigerant. At the inlet refrigerant is liquid & atthe outlet it has changed into gas.

Receiver dryer

Expansion Valve

Evaporator

CHAPILLARY TUBE

EQUALIZERCIRCUIT INCASE INTERNALAQUALIZERTYPE

VALVE

EQUALIZERPIPE

HEATSENSITIZING

TUBE

INLET

DIAPHRAGMCHAMBER

DIAPHRAGM

OUTLET

PRESSURESPRING

11

VENTILATION SYSTEM

HVAC CONTROL PANEL

This control panel has four knobs. Functionshandled by these knobs given below. The airflowcontrol switch has five positions for airflowdirection.

Slot - ‘A’ Blower Regulator

Blower off

Blower slow speed

Blower medium speed

Blower high speed

Slot - ‘B’ Air Distribution Control

- Air directed towards chest

- Air directed towards chestand legs

- Air directed towards legs

- Air directed towards legsand windscreen

- Air directed towardswindscreen (Demist /Defrost)

Demist : Switch-off heater. Direct airflow towards windscreen for a requiredperiod.

Defrost : Switch-on heater. Direct airflow towards windscreen for a requiredperiod.

Slot - ‘C’ - Fresh Air / Recirculation Operation

- Cab air recirculation

- Fresh air brought inside andcirculated.

D. Air Cooling Controls (for A.C., heating &demisting)

I. Ventilation

When the knob is in middle of the slot, the systemis in ventilation mode.

II. Air Cooling Control

AC temperature graduating scale is shown in bluecolour. Movement of the knob ranges from middleto extreme right to give gradually minimum tomaximum intensity of cooling. Keep blower in maxspeed for quick cooling effect.

III. Heater control

Heater control graduating scale is shown in redcolour. Movement of the knob ranges from middleto extreme left to give gradually minimum tomaximum intensity of heat. Flow of hot watersupply to heater coil is regulated by this knob.Keep blower in max speed for quick heating effect.

12

VENTILATION SYSTEM

Magnetic Clutch

It is part of AC compressor. It is used to connectand disconnect compressor from engine.

Its main components are stator, rotor with pulleyand pressure plate to engage drive pulley andcompressor magnetically.

Principle :

When current is fed to the coil, magnetic force isgenerated in iron II which attracts iron I.

Construction :

Stator is fixed on compressor housing andpressure plate is attached to compressor shaft.

Two ball bearings are used between inner surfaceof the rotor and front housing of compressor.

Operation :

When engine is operating, pulley is rotating sinceit is connected to crankshaft by belt, butcompressor does not operate until magnetic clutchis energized. When air conditioning system is on,current is supplied to stator coil. Electromagnetattracts pressure plate and pulls pressure plateagainst friction facing on pulley. Friction betweenfacing on pulley and plate causes clutch assemblyto rotate as a unit and drive AC compressor.

Magnetic Clutch

Principle

Construction

ATTRACTIVE FORCE

IRON(1)

SWITCH

IRON2BAT-

TERY

ATTRACTIVE FORCE

2 Hub

4 Ring Snap 1

3 Shrims

1 Bolt Flange

5 Stator7 Stator

6 Ring Snap 2

8 Compressor Assy.

ATTRACTED

ELECTROMAGNET

PULLEYSTATOR PRESSUREPLATE

13

VENTILATION SYSTEM

Vacuum Switching Valve (VSV)

It is a component of engine idling speed raisingdevice. It is provided to enable cooler operation ofAC system when vehicle passes through slowtraffic conditions.

Operation :

When switching on air conditioner, current flowsinto the coil, and VSV opens to vacuum source bymagnetic force.

Thus, vacuum will act on diaphragm of actuatorinstalled on FIP.

With the help of actuator accelerator lever ispushed to get higher idling rpm.

When switching off air conditioner, VSV opens toatmosphere side by compression spring forceallowing FIP lever to return to normal idle position.

Vaccum Switching Valve

Idling speed raising mechanism

Idling speed raising mechanism

COMPRESSIONSPRING

FILTER

COILMOVINGCORE

WHEN AIR CONDITIONER IS SWITCHED OFF

TO VACUUMTANK

VSV

ATMOSPHERE MAGNETICCLUTCH

DIAPHRAGM(VACUUM)

WHEN AIR CONDITIONER IS SWITCHED ON

TO VACUUMTANK

VSV

ATMOSPHERE MAGNETICCLUTCH

DIAPHRAGM(VACUUM)

14

VENTILATION SYSTEM

Dual Pressure Switch

Pressure switch is installed in the liquid line tubein cooling unit.

Pressure switch detects abnormally high or lowpressure of refrigerant in system and turns offmagnetic clutch to avoid compressor failure.

Standard pressure :

Low Side : 2.0 ± 0.20 Kg/cm2

High Side : 32.0 ± 2.0 Kg/cm2

The Switch will turn off automatically when lowside pressure is less than 2 Kg/cm2 and high sidepressure is more than 32 Kg/cm2.

Magnetic clutch gets actuated when blower switchand A/C switch are turned on under and refrigerantpressure is higher than 2.0 Kg/cm2.

Thermo amplifier and thermister

Thermister is a temperature-sensing device and isinstalled to sense the temperature of air dischargedfrom evaporator. When outlet air temperature fromevaporator goes below 3°C, amplifier senses thetemperature through thermister and switches offcompressor magnetic clutch.


EvaporatorThermo amplifier

CONTACTPOINT

TERMINAL &FIXED CONTACT

0-RING

CASE

PRESSURE

DIAPHRAGM

HOUSING

SPRING


15

VENTILATION SYSTEM

Removal and Fitment of A.C. Components1. Cooling unit Assembly

REMOVAL :

1. Discharge refrigerant with proper equipment.

2. Disconnect inlet & outlet pipes in enginecompartment from union of cooling coil.Properly plug unions and pipes openings.

3. Remove hoses at heater inlet and outlet end,in engine compartment. (In case of heater)

4. Properly plug at heater inlet and outlet endsto avoid any leakages of coolant. (In case ofheater)

5. Disconnect electrical connections for blowermotor, blower resistor, control panel etc. andremove all connectors of wiring harness fromcooling/heating unit.

6. Remove heater & face mode control cable.

7. Remove fasteners from mounting points ofcooling unit and remove unit from its location.Also remove drain hoses.

FITMENT

1. Assemble cooling unit and blower assemblywith proper fasteners.

2. Fit cooling unit with drain hose on the firewalland tighten fasteners.

3. Fit all connectors of vehicle wiring harness tocooling and blower unit.

4. Fit control cable for face mode and heatercontrol with cooling unit and control panel.Check for proper functioning of heater andfoot-face mode controls.

5. Connect refrigerant pipes to respecitive unionson firewall. Make sure that O-rings are intactand properly seated in their grooves. Applyfew drops of ND8 compressor Oil on O-ringsbefore fitment.

6. Remove plugs from the heater inlet and outletends.

7. Connect hoses to heater inlet and outlet ends.

8. Check the system for leakages and chargethe system with charge quantity of 670 ± 20gms.

Assembly cooling unit




16

VENTILATION SYSTEM

Assembly Evaporator

S. No Part Name

1 Adaptor Assy

2 Evaporator Sub Assy

3 Case Cooling Unit

4 Expanasion Valve

5 Thermister

EXPLODED VIEW OF ASSEMBLY EVAPORATOR

17

VENTILATION SYSTEM

2. Blower Assembly

Remove HVAC unit as explained above.

1. Remove fasteners connecting blower unit withfirewall and take out blower unit.

2. Replace blower unit with new one, if necessaryand assemble it on cooling unit.

3. Assemble complete cooling unit assembly tothe vehicle as explained above.

3. Blower Resistor

Blower resistor is meant for regulating blowerspeed. It is three-speed blower resistor and isalso provided with safety features. Whencurrent increases beyond limit blower switchesoff automatically.

1. Remove bottom part of the dash panel.

2. From the bottom of dash, resistor is visible.Take out wiring harness connector fromresistor.

3. Remove resistor by opening two screws.Replace it if necessary.

4. Connect wiring harness connector and fit dashpannel part as earlier.

4. Heater Assembly / Water Valve Assembly :

1. Remove complete HVAC unit and separate blowerassembly.

2. Remove plastic covers from HVAC unit to exposeheater assembly.

3. Pull out heater assembly along with water valveand pipes.

4. Disconnect hose on water valve by loosening andremoving clamps.

5. Reassemble in reverse order.

6. Fit HVAC on the vehicle.

Blower Case

Blower Motor

Assembly Blower

18

VENTILATION SYSTEM

Components of Blower System

EXPLODED VIEW OF ASSEMBLY BLOWER

S. No. Part Name

1 Blower Motor Assy

2 Case Blower RH

3 Case Blower LH

4 Bkt Assy Blower MTG

5 Resistor Blower

6 Plate

19

VENTILATION SYSTEM

5. Evaporator Assembly / Thermister /Expansion Valve

1. Remove HVAC unit & sepearate blowerassembly.

2. Remove evaporator case top by removingfasteners.

3. Carefully pull out thermister from evaporator coil.

4. Lift evaporator assembly from cooling case.

5. Disconnect expansion valve and tube &accessories.

6. Reassemble in reverse order.

7. Make sure that the remote bulb of expansionvalve is seated properly in dimple on suction tubeand secured by holder remote bulb beforecovering the expansion valve with insulatorpacking.

If remote bulb is loose on the pipe, expansionvalve will work erratically.

8. Use proper tools while loosening and tighteningnut and union joints on tubes.

9. Inset tube fully inside union half. Ensure that 'O'ring is properly fitted before tightening nut. Thiswill avoid damage to 'O' ring.

If 'O' ring is not fitted properly, it may get damagedleading to leakage after charging the system.

Evaporator Assembly

Evaporator Assembly

Cooling Unit

Expansion Valve

20

VENTILATION SYSTEM

6. Condenser Assy

1. Remove bumper assy.

2. Remove front grills.

3. Remove bolts on shroud assy to condensercore.

4. Take out shroud fan and replace if necessary.

5. Follow steps in reverse for assembly ofshroud on condenser core.

6. Fit back bumper assembly and grills.

7. Compressor Clutch :

1. Discharge system refrigerant.

2. Remove bolt flange on rotor.

3. Remove hub.

4. Carefully remove shims.

5. Remove ring snap

6. Remove rotor.

7. Remove second ring snap

8. Remove stator.

9. Replace defective items.

10. Follow steps in reverse for assembly.

11. Check clutch operation before fitment ofassembly.

12. Re-Charge the system.

Condenser

2 Hub

4 Ring Snap 1

3 Shrims

1 Bolt Flange

5 Stator7 Stator

6 Ring Snap 2

8 Compressor Assy.

Magnetic Clutch

21

VENTILATION SYSTEM

8. Receiver Dryer Bottle :


2. Remove inlet/outlet pipes.

3. Remove bolts on receiver dryer mountingbracket.

4. Replace receiver dryer bottle, if necessary.

5. Re-fix inlet/outlet pipes respectively.

6. Re-charge the system.

Note : Do not leave receiver dryer bottle unplugged.

9. Refrigerant Pipe Lines


2. Unscrew pipe joints and remove pipes thatneed to be changed.

3. Replace pipe.

4. Tight joints properly so that there is noleakage.

5. Re-charge the system.

Recharging Compressor Oil in the system

Compressor oil tends to mix with refrigerant andflow in the system. A portion of this oil alwaysremain in components like evaporator, condenseretc.

While changing compressor, flush the system withnitrogen gas to remove any oil left in the system.This will prevent reduction of cooling efficiency dueto excess oil in the system.

Compressor oil can be charged in compressor onlywhen there is no gas in the system. This can bedone by pouring oil from suction side of compressorby removing suction hose.

Please do not charge oil when refrigerant is presentin the system.

Avoid presence of moisture while rechargingcompressor oil.

Do not keep compressor oil bottle cap in opencondition. Since oil is highly hygroscopic, it willcatch moisture.

Receiver Dryer

Refrigerant Pipe Lines

22

VENTILATION SYSTEM

SAFETY FEATURES OF THE SYSTEM

Following are the safeties provided in the system.

1. Dual pressure switch

2. Thermo amplifier and thermister

3. Safety valve on compressor

GAS AND OIL

Refrigerant used in the system is R134a

Gas charge quantity 670gms ± 20gms

Oil ND 8

Oil charge quantity 80CC ± 20CC.

While gas refilling or changing component likecondenser, evaporator, receiver dryer etc. charge20CC ND-8 oil.

23

VENTILATION SYSTEM

TROUBLE SHOOTING

DO'S AND DONT'S FOR AIRCONDITIONING SYSTEM

S.No DO'S

1 Clean condenser during periodical service of thevehicle

2 Maintain proper refrigerant level.

3 Add recommended oil quantity in compressorduring refrigerant charging.

4 Clean evaporator periodically to remove dust andforeign particles.

5 Adjust fresh air and heater cable properly to closedamper firmly.

6 Educate customer on proper usage of A/Ccontrols

7 Maintain proper engine ilding rpm.

8 Maintain coolant level and ensure proper enginetuning

9 Maintain proper AC belt tension

REASON

Dirty & clogged condenser results in A/C tripping and lesscooling

Less refrigerant results in less cooling

Adequate quantity of oil prevents poor pumping andpremature wear of compressor components.

Clogged evaporator results in less airflow and reducedcooling.

Unadjusted cable will result in less airflow and reducedcooling.

Proper usage of A/C controls will give optimum cooling.

Less idling rpm will result in stalling of engine and lesscooling

This will prevent overheating of engine.

Loose belt will slip and over tight belt will result in noiseand premature failure of magnetic clutch.

S.No DONT'S

1. Do not use A/C with fresh air mode open.

2. Do not operate A/C with heater on.

3. Do not operate A/C with out refrigerant in thesystem.

4. Do not leave A/C joints open

5. Do not charge refrigerant in the system withoutproper vacuum.

6. Do not check A/C system for leaks with more than20-kg/cm2 pressure.

REASON

This will lead to mixing of outside air with cool air in sidethereby reducing cooling effect.

This will result in mixing of hot air with cool air.

This will result in failure of compressor.

Moisture tends to enter A/C system if joints remain openfor long time.

Will result in no or low cooling.

This may result in damage to A/C components on lowpressure side.

24

VENTILATION SYSTEM

S.No CHECK POINT NORMAL CONDITION RESULTS

A

B

Fresh air/recirculation position

Air direction lever position

Temperature control lever position

Grill direction

Should be in recirculation mode

Should be in face mode

Should be in maximum cool position

Center grill towards rear seat. Sidegrills towards co-driver and driverseat

Will stop entry of hot air from outside

Will ensure proper cooling

Will ensure that heater is not workingwith A/C on.

Will ensure proper distribution of coolair in cabin.

Condenser surface

Engine coolant level

Engine tuning

Belt tension

Should be clean and dust/dirt free

Should be on maximum level

Should be as per manufacturer'sspecification

Belt should not be too loose or tootight

Will ensure total liquidification ofrefrigerant

Will prevent engine over heating.

Will prevent engine over heating andminimise fuel consumption.

Loose belt will slip and affect A/Cperformance.

Tight belt will damage compressormagnetic clutch.

PASSENGER CABIN

ENGINE ROOM

A/C CHECK POINTS

25

VENTILATION SYSTEM

REFRIGERANT (R 134a )(Tetra flouro ethane, CF3-CH2F)

R134a refrigerant is used in the system.

It is a hydro fluro carbon (HFC) which has no ozonedestructive potential and its global warmingpotential is very much lower than that of R 12refrigerant.

Form ...................................... Gas.

COLOUR................................. Colourless.

Smell ..................................... Slightly of ether.

Crystallisation temperature ..... -1170 C.

Boiling temperature ................. -260C.

Safety Precautions:

It is a safe refrigerant, i.e. non-flammable, nonexplosive, non-irritating and without smell.Precautions given below should to be taken whilehandling this refrigerant :

* Avoid any form of contact with liquid refrigerant.Wear safety glasses for eye protection. In caserefrigerant gets into your eyes, immediately seekmedical help. Do not rub eyes.

* In the event of work involving refrigerant circuit,refrigerant must not escape into atmosphere.

* Suitable suction/ extraction system orreprocessing systems are to be used.

* Refrigerant must not be released in confinedspaces. As it is heavier than air, the danger ofasphyxiation exists.

* Under no circumstances may parts of thesystem be cleaned from inside with superheated steam or compressed air. Only usenitrogen for cleaning.

* Refrigerant is completely non - toxic at normaltemperatures. However it decomposes uponcontact with flames or higher temperatures, toform hydrogen chloride and hydrogen fluoride.These products are hazardous to health.Therefore, under no circumstances, shouldwelding be carried out on the closed system orin its close proximity.

Ozone destructive potentialGlobal warming potential

* Switch off the system if a part of the air -conditioner system is damaged or leaking, dueto some reason for example, a vehicle accident.

This is to avoid damage to the compressorrunning in the absence of refrigerant.

Properties of R134a refrigerant

CFC HFC

26

VENTILATION SYSTEM

COMPRESSOR OIL

Compressor oil is necessary for lubrication ofcompressor bearings, moving and sliding surfaces.

Compressor oil circulates through entirerefrigeration cycle. Only recommended oil must beused.

Compressor Oil Quantity

When air conditioner is operated, some amount ofoil is discharged together with refrigerant fromcompressor and circulates in the system.

If the amount of oil discharged by the compressorinto the refrigeration cycle is very small, there willbe hardly any adverse effect on refrigeration cycle.Instead, there will be benefit of improvinglubrication of various valves in the system.

Conversely, if there is a large amount of oilcirculating through refrigeration cycle troubles maydevelop.

Refer trouble shooting chapter.

Caution

Oil

ND oil 6 is used on system with CFC 12refrigerant. It doesn’t dissolve in HFC 134arefrigerant. If this oil is used on HFC 134a system,life of compressor will greatly reduce.

Therefore, ND-OIL 8 for 10 P(A) type compressoronly to be used.

To distinguish HFC 134a, a sticker is pasted oncompressor body as shown.

O rings

O-rings of piping connectors that are used in CFC12 system and those that are used in HFC 134asystem are not interchangeable. If O-rings for CFC12 system are used by mistake in the connectionsof an HFC 134a system, O-rings will foam andswell, resulting in leakage of refrigerant.

Therefore, always use genuine O-rings suitable forHFC 134a system.

Label for Vehicles Equipped withHFC 134a Air Conditioning Systems

R134aUSE ONLY NDOIL 8

Sticker on AC Compressor

Sticker on AC Compressor

27

VENTILATION SYSTEM

SERVICE AND REPAIR

Service Tools and Gas Leak Detector(FOR HFC 134a)

Service Tools

Special service tools are required for servicing airconditioner to prevent incorrect refrigerant chargingand to prevent compressor oil from getting mixed.

Service Tool List for HFC 134a

Sr. No. (Metric size )

1. M10X P 1.5 Adaptor

2. M12 X P 1.75 High pressure sideAdaptor

3. “Quick - disconnect adapter which meetsSAE standard (High pressure side)

4. Quick - disconnect adapter which meetsSAE Standard (Low Pressure side)

5. M14 X P 1.25 D-Spanner

6. Vaccum pump adaptor

7. Belt tension guage

Inspection

1. Check condenser fins for blockage or damage.If the fins are clogged, wash them with water.Be careful not to damage fins.

2. Make sure that drive belt is installed correctly.

Check that drive belt fits properly in ribbedgrooves.

3. Check drive belt tension.

Using a belt tension gauge, check drive belttension.

Drive belt tension checking tool

Service tool set for HFC-134a

BORROUGHSNIPPONDENSO

MANIFOLDGUAGE

CHANGINGHOSE

QUICK DISCONNECTADAPTER

VACUUMPUMPADAPTER

SERVICE CANT JOINT

SERVICE CANVALVE

1

1

14

2

3

6

7

28

VENTILATION SYSTEM

4. Start engine.

5. Turn on A/C switch.

Check that A/C operates at all positions ofblower switch. If blower does not operate, checkcircuit breaker.

6. Check magnetic clutch operation.

If magnetic clutch does not engage, check A/Cfuse.

7. Check that idle speed increases. When magneticclutch engages, engine speed should increase.

8. Check that condenser fan motor rotates.

9. If there is no cooling or it is insufficient, inspectfor leakage.

If piping connections are soiled with oil, itindicates leakage of refrigerant. Inspect by gasleak detector and retighten loose connectors, ifnecessary.

Retightening of pipe connections must be doneusing two wrenches to avoid twisting of tubing.

10 Check the Amount of Refrigerant.

a. Operate the air conditioner under conditionsshown in table given below :

CHECK OIL LEAK

Leak in pipe joints

LOOSENING

OVER TORQUING

WRONG

Leak in pipe joints

Note: When ambient temperature is more than 40OC(113OF) and the pressure on the high pressuregauge becomes 1.86 MPa (19 kg/ cm2G) or morewith the conditions in table, run the engine atidling speed to cool down condenser.

If high pressure gauge still indicates too high,perform this test in a cool place. Open all doorsand set blower speed to LOW.

Item Condition

Doors Completely open

Temperature setting Maximum cooling

Air flow direction Air to face vents

Blower speed High

Air Circulation Switch Recirculation Mode

Engine speed (HFC 134a) 1500 rpm

A/C ON

29

VENTILATION SYSTEM

b. Check the Amount of Refrigerant.

1. Check sight glass on receiver dryer.

Appropriate quantity:

No bubbles. Occasionally bubbles appear.

Excessive quantity:

No bubbles. In this case, high and lowpressures will both be high. So cooling will beinadequate. Check manifold gauge.

Empty :

No bubbles. Check manifold gauge.

Insufficient refrigerant:

Bubbles visible. (Continuous flow of bubbles)

2. Check the amount of refrigerant as perinstructions given in table below :

INSUFFICIENT

APPROPRIATE

SIGHT GLASS

Sight glass indications (If fitted)

EXCESSIVE

Item Symptom Amount of Refrigerant Remedy

1. Bubbles present in sight glass Insufficient Check for leak with gas leak detector

2. No bubbles present in sight glass Empty, proper or too much Refer to items 3 and 4

3. No temperature difference between Empty or nearly empty Evacuate and charge system. Thencompressor inlet and outlet check for leak with gas leak detector.

4. Temperature between compressor Proper or too much Refer to items 5 and 6inlet and outlet is noticeably different

5. Immediately after air conditioner is Too much Discharge excessive refrigerant.turned off, refrigerant in sight glassstays clean.

6. When air conditioner is turned off, Empty, proper or too much Refer to items 3 and 4refrigerant foams and then stays clear

30

VENTILATION SYSTEM

Charging A/C system:

1. Installation of Manifold Gauge

a. Close both high and low pressure valves ofmanifold gauge.

b. Connect low pressure hose to low pressurevalve and high pressure hose to high pressurevalve. Tighten hose nuts by hand.

Do not apply compressor oil to the seats ofconnection.

2. Evacuate Air in Refrigeration System

a. Connect center hose of manifold gauge tovacuum pump inlet.

b. Open both high and low pressure valves andrun vacuum pump.

When opening low pressure valve, if needle ofhigh pressure gauge falls to vacuum range,there is no blockage in the system.

c. After about ten minutes, check that lowpressure gauge indicates more than 600 mmHg(23.62 in Hg, 80.0 kPa) of vacuum.

If reading is not more than 600 mmHg (23.62 inHg, 80.0 kPa), close both valves and stopvacuum pump. Check system for leaks andrepair if necessary.

If no leaks are found, continue evacuating air inthe system.

d. Continue evacuating air in the system until lowpressure gauge indicates a vacuum of 750mmHg (29.53 in Hg, 99.98 kPa).

e. Close both high and low pressure valves andstop vacuum pump. Leave the system in thiscondition for five minutes or longer and checkthat there is no change in gauge indication.

CLOSED

OPEN

AIR

OPEN

CLOSED

Manifold Gauge

Connections to Manifold Gauge

31

VENTILATION SYSTEM

3. Install Refrigerant Service Can Tap Valve

Do not open high and low pressure valves ofmanifold gauge.

Press schrader valve on the side of manifoldgauge set and expel air from center hose.

Press schrader valve until refrigerant come outof it.

Note :

Schrader valve is part of manifold gauge. Thisvalve is used to open or close the suction anddischarge lines to respective pressure gagues.

4. Inspect Refrigeration System for Leaks

After evacuating air in the system, check thesystem for leakage.

a. Open high pressure valve to charge the systemwith refrigerant vapour.

When refrigerant service can is placed right sideup, refrigerant will enter the system as avapour.

b. When low pressure gauge indicates 1 kg/cm2

(14 psi, 98 kPa) pressure, close high pressurevalve.

c. Using gas leak detector, check the system forleakage.

If leak is found, repair faulty component orconnection.

HANDLE

CONNECTION

CLOSED

PRESS

Normal condition

closeLO gauge

kg/cm214 psi 98

kPa

DISC

CLOSED

CLOSED OPEN

( )

OPEN

Insufficient refrigerant

32

VENTILATION SYSTEM

TROUBLE SHOOTING

Trouble shooting can be divided into three parts.

i] Visual & audio inspection of AC system (ACidle up check)

ii] Trouble shooting by using manifold gauge.

iii] Trouble shooting of electrical circuits.

Simplest to detect trouble is by looking andlistening to AC system components.

Defects related to refrigerant cycle can beinvestigated by using manifold gauge.

When visual and audio inspection of AC system isOK and low side / high side pressure in manifoldgauge is within specified limits, complaint may bedue to fault in electrical circuits for blower/cooler ordue to faulty components.

Specified refrigeration cycle pressures :

Low side : 1.5 to 2.5 kg/cm (0.15 to 0.25 MPa)

High side : 14 to 16 kg/cm (1.37 to 1.57 MPa)

i. Visual and Audio Inspection of AC System :

Start engine and run it at idling speed. Switch onblower and AC switches. Check blower operation,magnetic clutch operation, air temperature at ACoutlet, etc.

Look for conditions given below :

1. Is the drive belt loose?

2. Are the condenser fins covered with dirt anddust?

In this case, condenser cooling effect will begreatly reduced. As a result, cooling capacityalso will decrease.

3. Is the air filter clogged?

A clogged air filter will reduce air flow and lowercooling capacity.

4. Can oil stains be seen in refrigeration cycleconnections and joints?

A place that shows oil stain indicates thatrefrigerant is leaking from that place togetherwith compressor oil.

5. Check for bubbles in receiver dryer sight glass.

6. Check for abnormal noise from AC systemcomponents

ShaftCompressor

Magnetic clutch

Cylinder head

Worn or damage bearing

Contact between stator and rotor

Loose mounting screw on stator

Upside down blower motorBlower motor

Crank pulley

V- Belt

Loose blower mounting

Loose Pulley

Improper tension

Wrong mountingIdle Pulley.

Worn or damage bearing

Wrong fastening or mounting ofbracket or clamp

Wrong clearance

Other pipingparts

If visual and audio inspection does not reveal anydefects proceed trouble shooting by using manifoldgauge.

Install manifold gauge to refrigeration cycle.

Prepare multimeter and gas leak detector.

33

VENTILATION SYSTEM

Normal condition

Insufficient refrigerant

2. Insufficient Refrigerant :

Problem Cause Check andremedy

1. Pressure is low on Quantity of, -Check for gasboth low refrigerant is leakage and repairpressure and too small- -Replenishment ofhigh pressure refrigerantsides If indicated pressure

2 Bubbles can be Gas leakage is near 0 whenseen in sight connected to gauge,glass. evacuate air

3. Air being blown after checking andout is not cool. locating leak.

ii. Trouble Shooting by using Manifold Gauge :

Manifold gauge indicates refrigeration cycle highand low pressure side pressures on respectivegauge.

Important

Be sure to purge out air in charging hoses ofmanifold gauge by using refrigerant pressure incycle.

1. Under Normal Conditions :

* After the engine has warmed - up, check thefollowing conditions (for HFC 134a).

Engine Speed : 1500 rpm

A/C inlet temperature : 30O-35O C (86O- 95O F)

Blower Speed : HlGH

Temperature control : Maximum cooling.

Reference

Gauge indications before A/c operation

Both high and low pressure sides:

5-8 kg/cm2 (0.5 - 0.8 MPa)

34

VENTILATION SYSTEM

3. Refrigerant Fails to Circulate(Cycle Is Clogged Up)


1 when completelyclogged up -Check receiver,Vacuum is imme- expansion valves,diately indicated ERR, etc.on low pressure -A tempreatureside. Clogging of difference occurs

A/C cycle between IN and OUT2. When slightly of defective

clogged up parts.Vacuum is gradu- -Be Sure toally indicated on evacuate air afterthe pressure finishing remedy.side

4. Moisture Entered in the Cycle


1. Air conditioneroperates Freezing of -Check expansionnormally at the expansion valve, etc.beginning, but valve due to -Replace receiverover time, vacuum presence of (or dryer)is indicated moisture Be sure toon low pressure evacuate air afterside. finishing remedy.

5. Compressor Compression Failure


1. Pressure on low - Check compressor.pressure side is In case ofhigh; pressure on malfunction,high pressure compressor will notside is low. Compressor be hot to touch.

2. When A/C is defectturned offlow and highpressure sidessoon equalize.

Refrigeant fails to circulate

Moisture entered in cycle

Compressor compression failure

35

VENTILATION SYSTEM

6. Excessive Refrigerant, or InsufficientCondenser Cooling

Problem Cause Check and remedy

1. Pressure is high Excessive - Check refrigeranton both low refrigerant quantity.pressure and high - Slowly vent outpressure sides. refrigerant if

overcharged.- Check and repair

2. Bubbles can not Poor condenser fan.be seen in condenser - Check enginesight glass cooling cooling system.

7. Air Entered in the Cycle


1. Pressure is highon both lowpressure and high - Replace refrigerantpressure sides. Be sure to

2. Low pressure Entry of air evacuatepiping is hot to in cycle air after finishingtouch. remedy.

3. Bubbles arevisible in sightglass

8. Expansion Valve Opens too Far


1. Pressure is high - Check expansionon both low valve.pressure and high - Check installationpressure sides. condition of

2. Frost (dew) Expansion tempreratureappears on low valve fault sensing bulb.pressure side - This problempiping frequently occurs

after replacingexpansion valve

Excessive refrigerant or insufficient condenser cooling

Air entered in the cycle

Expansion valve opens too far

36

VENTILATION SYSTEM

iii. Troubleshooting of Electrical Circults :

Chart given below indicates items to be checked for various types of troubles :

No. Troubles Main Inspection Areas Others

Fuses Connectors Wiring Body Servo SensorHarness Ground Motors Circuit*

1 Fuse is blown easily O O O O

2 No blower operation O O O O Heater relay, Blower motor,Blower resistor, Blower switch

3 Blower speed does not change O O O O Blower Resistor, Blower Switch

4 No compressor operation O O O O Magnetic clutch & relay,Compressor, Heater relay, A/C sw.

5 A/C lamp does not light O O O O Engine RPM signal lines, A/C switch

6 No A/C operation O O O O O (No cool air comes out)

7 Cabin temp. does not decrease O O O O O O(insufficient cooling)

8 No warm air comes out O Engine coolant volume, A/C temp.Control lever, Heater radiator

9 No condenser fan operation O O O O O Relays (for condenser fan, radiatorfan), Condenser fan motor, condenserfuse.

10 No engine idle-up when A/C is on. O O O Idle-up VSV, Idle-up actuator, Vacuumhose line

Note: * Sensors are thermister, pressure switch and water temp. switch.

37

VENTILATION SYSTEM

Troubleshooting Flow Chart

After making sure that the blower circuit operation is good, troubleshoot the cooler circuit in the followingprocedures.

STEP 6 CHECK INPUT TO AMPLIFIER

With blower operated, push onA/C switch, and check whetherA/C switch lamp is lit.

No

With A/C switch and blowerswitches On, check whethermagnetic clutch is On. Yes

Check voltage of 1 - poleconnector for the magnetic clutch.

Check voltages to clutch relay Connector

No Battery Voltageor No Grounding

Check output voltage fromamplifier.Terminal 1A – OK

No Good

InspectA/C fuse

OKBlown orBad Contact

Check wiring betweenA/C fuse and the blowercircuit.

Check magnetic clutch coil.

Step 4-1

Check relay and its wiring

Check continuity of wiringbetween amplifier and magneticclutch relay.

Check inputvoltage toA/C fuse 12V

Replace it

CheckA/C

switch

Check condenserFan relay circuit

12V

OK

OK

OK

Check each input voltage and signal fromsensor such as Thermistor, DualPressure S/W Engine RPM signal fromeng. ECU. Also check the earth circuitfor amplifier.

OK

Replace amplifier

Check sensor and its wiring,which don't input correct signal.

ImportantAlso A/C idle up check should be done Visuallsyregardless of above troubleshooting result,

No

No Good

OK

STEP 1 CHECK A/C SWITCH FUNCTION

STEP 2 CHECK MAGNETIC CLUTCH

STEP 3 CHECK POWER SOURCE TO CLUTCH

STEP 4 CHECK MAGNETIC CLUTCH RELAY

STEP 5 CHECK OUTPUT FROM AMPLIFIER

38

VENTILATION SYSTEM

A/C PERFORMANCE CHECK UP PROCEDURE

STEP - I

- Open doors

- Check and adjust position of:

(a) Fresh/recirculation control

(b) Air direction control

(c) Temperature control

(d) Grill direction

STEP - II

- Open engine bonnet

- Check

(a) Condition of condenser surface-cleancondenser with low pressure water ifrequired

(b) Level of coolant - top up if required

(c) Belt tension - use belt tension checkinggauge

STEP III

- Close both suction and discharge valvesof manifold gauge.

- Install manifold gauge

(a) Blue hose to suction side

(b) Red /orange hose to discharge side

(c) Yellow hose free to air

STEP IV

- Start engine

- Check and adjust engine idling rpm. Userpm meter

STEP-V

- Switch on blower to maximum speed.

- Switch on a/c switch

STEP-VI

- Check the function of engine idlingspped raising device. Adjust engine rpmto 1000 if necessary

STEP-VII

- Check pressure on suction anddischarge side gauges.

- Between 1500/2000 rpm & at an ambienttemperature of 35 to 40Oc suctionpressure should be 2 to 3 kg/cm2 anddischarge pressure should be 15to 18 kg/cm2

- Check sight glass on receiver dryer

- If refrigerant is adequate glass will beclear

- If refrigerant is less glass will showexcessive bubbles

STEP VIII

If refrigerant level is low

(a) Switch off a/c and engine

(b) Check refrigerant leakage by using leakdetector and soap solution

STEP IX

- Release all refrigerant

- Repair leakage and check again

- Vacuum a/c system by using vacuumpump

- Recharge refrigerant

STEP X

- Check a/c performance - usethermometer

- Sit on driver seat

- Close all doors and windows

- Start engine

- Switch on blower to maximum speed

- Install thermometer in centre grill

- Thermometer reading should be between10Oc & 12Oc within 10 minutes at anambient temperature between 35Oc &40Oc.

1

HEATING & VENTILATION SYSTEM

HEATING & VENTILATION

3


INTRODUCTION :

Two types of ventilation systems are available asoption in Tata TL.

1] Heating and Airconditioning (HVAC)

2] Heating

In heating arrangement temperature of air iscontrolled by adjusting flow of engine coolantthrough water valve and blower speed.

In both arrangements provision has been made fordemisting windshield glass and door glasses.

This section deals with heating system.

5


CONTENTS :


1. Exploded view of heater unit 7

2. Basic components of heater unit & their functions 8

3. Procedure for removal & fitment of heater components 10

4. Do's & Don'ts for Cab heating system 12

5. Trouble shooting chart 12

7


1 ADAPTOR ASSY

2 HEATER SUB ASSY

3 CASE HEATER UNIT

4 BRACKET ASSY DUCT MOUNTING

5 HOSE DRAIN

6 BRACKET DUCT MOUNTING

7 BLOWER ASSY

8 BOLT FLANGE

9 STAY BRACKET

S.No. Part Name

Heater Unit (Exploded view)

8


AIR HEATING SYSTEM – FULL AIR MIX TYPEFresh air/recirculation valve & water valve can beadjusted manually to achieve desired temperaturein cabin.

BASIC COMPONENTS

The circuit consists of following basic components.

Heater casing with heater coil

Air blower assy

Water control valve (Coolant)

Control panel

OPERATION OF COMPONENTS :-HEATER CASING WITH HEATER COILIn casing, there is a serpentine heater coil havinginlet and outlet for radiator coolant water. Air fromblower passes out side the serpentine tube andfins, hot coolant water from radiator inside thetubes. Air gain heat energy from water and itstemperature increases instantaneously. More thewater flow rate, more is the air outlet temperaturefrom the system.

When heater is ON, it is always advisable to mixfresh air in the system to avoid dehydration ofpassengers in cabin.

BLOWER ASSYFunction of blower is to generate air flow on heatercoil which increase the temperature inside cabin.Toachieve desired heating effect, air flow can becontrolled by controlling speed of the blower.Blower speed can be increased or decreased bysliding knob on the control panel with the help ofblower resister. In lower blower speed, temperatureof the air is always higher.

WATER VALVEFunction of water valve is to control water flow ratein side cooling coil. It is mounted in the enginecabin side on the inlet pipe. Water flow rate alsocontrol cabin temperature. Water valve can becontrolled by knob on the control panel.

Heater Unit (Exploded view)

Blower Motor

Water Valve

9


CONTROL PANEL

This system has full heating, and ventilation.System controls can be adjusted to mix these intovarious combinations. Air flow into the interiorthrough different locations is controlled by switch(A) fitted on RH side top of control panel. Air flowcontrol switch has five positions for air flowdirection.

Switch A : Air Distribution Control

Air to face vents

Air to face vents and forfoot lets

Air to foot lets

Air to foot lets and wind screenrecommended for clearing mildmist on wind screen.

Air to wind screen recommendedfor clearing heavy fog or snow.

Switch B : Temperature Control.

This switch is at bottom RH side of panel. Toachive maximum heating effect slide the knobtowards red region.

Switch D : Blower Regulation

This switch is on top LH side of panel. This switchis for controlling blower speeds as given below.Blower speed could be selected as perrequirements.

Switch C : Fresh Air/Recirculation Option

This switch is provided on bottom LH side of panel.It has got two positions. Move the lever for desiredair circulation mode.

Control Panel

D A

C B

Blower off

Blower slow speed

Blower medium speed

Blower high speedFresh air brought

inside and circulatedCab air recirculation

Fresh air valve (open position)

Fresh air valve (closed position)

10


Removal and Fitment of heater Components1. Heater unit Assembly (LHD and RHD)REMOVAL :

To replace the heating unit, following sequence tobe followed.

1. Discharge coolant with proper equipmentand store in some vessel.

2. Disconnect inlet & outlet pipes in enginecompartment after loosening pipe clampbefore water valve. Put proper plug on inletand outlet of heater pipe openings.

3. Remove hoses at heater inlet and outletend, in engine compartment. (In case ofheater)

4. Put proper plug at heater inlet and outletends to avoid any leakages of coolant.

5. Disconnect electrical connections forblower motor, blower resistor, control paneletc. and remove all the connectors of wiringharness from the heating unit.

6. Remove heater & face mode control cable.

7. Remove fasteners from mounting points ofheating unit and remove the unit fromvehicle. Also remove drain hoses.

FITMENT

1. Replace heating unit with new one andassemble it with blower assembly withproper fasteners.

2. Fit heating unit with drain hose at thepositions on firewall and tighten fastenersat specified positions.

3. Check and ensure that all connectors ofwiring harness are fitted with heating andblower unit.

4. Fit the control cable for face mode andheater control with the cooling unit andcontrol panel. Check for proper functioningof heater and foot-face mode controls.

5. Remove plugs from heater inlet and outletends.

6. Connect hoses to heater inlet and outletends.

7. Check system for leakage and fill it withcoolant.

Assembly Heater unit

Heater Assembly

Exploded view of Heater Assembly

Heater Sub Assembly

1. Adaptor Assy.2. Heater Sub assy.3. Case heater unit

11


2. Blower Assembly

1. Remove fasteners connecting blower unit withfirewall and take out blower unit.

2. Replace blower unit with new one and fit withfasteners on the heater unit.

3. Assemble heater unit assembly on the vehicleas explained above.

3. Blower Resistor

Blower resistor is meant for regulating blowerspeed. It is three-speed blower resistor and is alsoprovided with safety features, which blows it offwhen current increases beyond limit.

1. Remove bottom part of the dash panel.

2. From the bottom of dash, resistor is visible.Take out the wiring harness connector fromresistor.

3. Remove the resistor by opening two screwsand replace it with new one.

4. Connect wiring harness connector and fit dashpanel part as earlier.

Blower Case

Blower Motor

1 Blower Motor Assy

2 Case Blower RH

3 Case Blower LH

4 Bkt Assy Blower MTG

5 Resistor Blower

6 Plate

Exploded view of Blower Motor assembly

12


TROUBLE SHOOTING

DO'S AND DONT'S FOR HEATING SYSTEM

REASON

Dirty & clogged heater core results in less heating and airflow.

Unadjusted cable will result in less airflow and reducedperformance.

Proper usage of heating controls will give optimumperformance..

Less rpm will result in less heating of engine and lesscabin temperature.

This will ensure the proper flow of coolant in the heatercore.

Troubleshooting of Electrical Circults :

Chart given below indicates items to be checked for various types of troubles :

No. Troubles Main Inspection Areas Others

Fuses Connectors Wiring Body Servo SensorHarness Ground Motors Circuit*

1 Fuse is blown easily O O O O

2 No blower operation O O O O Heater relay, Blower motor,Blower resistor, Blower switch

3 Blower speed does not changes O O O O Blower Resistor, Blower Switch

4 Less or no heating O O Also check the coolant water level inradiator.

5 No warm air comes out O Engine coolant volume, TemperatureControl lever, Heater radiator

Note: * Sensors are thermister, pressure switch and water temp. Switch.

REASON

This will lead to low relative humidity in the cabin anddehydration of the passengers.

S.No DO'S

1 Clean heater core periodically to remove dust andforeign particles

2 Adjust fresh air and heater cable properly to closedamper firmly.

3 Educate customer on proper usage of heatercontrols

4 Adjust proper engine rpm.

5 Check coolant level and ensuring proper enginetuning

S.No DONT'S

1. Do not use heater for long time in recirculationmode.

1


PRODUCTIMPROVEMENTS

3


INTRODUCTION

This section deals with improvements &modifications carried out in recent past & whileintroducing face lift version.

Modifications incorporated on G-76 Gear Box appearin the supplement section of gear box.

Please recheck part numbers in updated partscatalogue while ordering modified parts.

5


CYLINDER HEAD GASKET

EXISTING (NON RE TORQUE)

Old Part No. : 2547 0115 53 22 (Reinz 1.6 mm) / 2547 0115 5323 (Reinz 1.7 mm)

NEW MLS GASKET Introduced from April ‘03

MULTI LAYER STEEL GASKET (ReinzGermany) WITH MODIFIED CYLINDERBLOCK INTRODUCED IN PLACE OFNON-RE TORQUE GASKET.

NOTE :Old gasket can fit on new cyl. blockNew gasket can not fit on old block dueto gasket bridge configuration.There is no change in cyl. Head mountingbolt and torque for head mounting .

CHANGES DUE TO METALLIC (MLS) CYLINDER HEAD GASKET

Component Name Old Part no. New part no. Change in Parameter

Assy. Cylinder Crank 2547 0110 0196 2547 0110 0237 1. Slit width changed to 1.6 mm-0.10case with Liners from 2.0 MM-0.2

2. Relieving for rivets

Cylinder Crank case 2547 0110 3729 2547 0110 3739

Cylinder Head NA 2547 0115 3817 2547 0115 3823 Relieving for rivets

Cylinder Head TC 2547 0115 3815 2547 0115 3824

Valid Part Numbers for new MLS cylinder head gasket :

Part No. Identification Mark / No. GasketThickness

2547 0115 5361 60 – 33155 – 40 1.5 mm

2547 0115 5362 60 – 33155 – 50 1.6 mm

6


CYLINDER HEAD COVER GASKET

CYLINDER HEAD COVER GASKET PROFILEMODIFIED WITH THICKER SECTION FORBETTER SEALING.

Introduced from Mar. 2001

OLD PROFILE MODIFIED PROFILE

ENGINE - CYLINDER HEAD

New part No. : 2547 0115 0195

ASSY. CYL. HEAD, W/O VALVES(INTERMEDIATE)

Old part No. : 2547 0115 0130

ASSY. CYL. HEAD, W/O VALVES(INTERMEDIATE)

Locating dowels provided on cylinder head and cam shaftcap to control bore mis match/ ensuring better alignment,when reassembled again for camshaft fitment on 4DLTCengines. This avoids cam shaft oil seal leakage

Introduced from Feb. 2003

7


TURBO CHARGER GASKETS

STEEL BACK BONE GASKET FORBETTER SEALING.

Old part no. 2547 1413 5302

OLD – NON ASBESTOS

OLD – METAL GASKET

OLD – METAL GASKETWaste gate hose

Valid Part Numbers:

1. Turbocharger assy-2547 1451 0104

2. Gasket Turbine inlet -2547 1411 5332

3. Gasket Turbine outlet - 2547 1411 5333

STAINLESS STEEL MATERIAL (SS304)FOR HIGH HEAT RESISTANCE

Introduced from October ‘02

New part no. 2547 1413 5304

TIMING BELT

GD100 (M/s GATES , GER-MANY) MAKE BELTS INTRO-DUCED FOR IMPROVED LIFE.

Introduced from May ‘02

• NOTE : INTERCHANGEBLE

OLD PART NO:2547 0511 6301

NEW PART NO:2547 0511 6310

8


OIL RETURN LINE (TURBO CHARGER)UN MODIFIED

Oil outlet tube 2547 1817 0154

Oil outlet rubber hose 2547 1817 5807

MODIFIED

METAL TUBE LENGTH REDUCED& HOSE LENGTH INCREASED FORBETTER FLEXIBILITY.

Note: If the oil outlet pipe & hose of old version (Part No: 2547 1817 0138, 2547 1817 5805) is replaced with newversion (Part No: 2547 1817 0154, 2547 1817 5807) it is essential to fit new version oil inlet pipe (Part No: 25471817 0153)

VACUUM BRAZING &IMPROVED FORMINTRODUCED.

Introduced from October ‘02

SILICON RUBBER HOSEINTRODUCED FOR HIGH HEATRESISTANCE

WATER PUMP ASSEMBLY

NON UNITISED SEAL

UNITISED SEAL ASSEMBLYINTRODUCED FOR BETTERWATER SEALING.

Introduced from July ‘01

9


BELT (ALTERNATOR)

SINGLE GROOVE

SIX GROOVE

SIX GROOVE DRIVE BELT ARRANGEMENTINTRODUCED IN PLACE OF SINGLE GROOVEFOR IMPROVED BELT LIFE

Introduced from JULY-2003

FAN BEARING HOUSING

ALUMINIUM HOUSING

CAST IRON HOUSING

Old part no. : 2547 2015 0112(assy. Bearing housing comp.)

CAST IRON BEARING HOUSING INTRODUCEDIN PLACE OF ALUMINIUM TO ELIMINATE BEAR-ING FAILURES CAUSED DUE TO DISTORTIONOF ALUMINIUM HOUSING

Introduced from Oct ‘02

New part no. : 2547 2015 0124(assy. Bearing housing comp.)

2547 2015 3718( Fan Bearing housing)

10


CLUTCH SLAVE CYLINDER

FRONT EXHAUST PIPE

M/s KBX MAKE SLAVE CYLINDER ASSEMBLYINTRODUCED TO ELIMINATE SEAL WEAR(EPDM SEALS & BETTER BORE SURFACE FINISH)

DIMPLE FORM CORRECTED FOR BETTERACTUATION OF CLUTCH

Introduced from Mar ‘02

EXHAUST PIPE WITH FLEXIBLE JOINT INTRO-DUCED TO ELIMINATE FAILURE OF CATALYTICCONVERTOR

Introduced from APR-02

Old. part no. 2701 4920 0124

New part no. 2721 4920 0120

11


RADIATORCOPPER BRONZE RADIATOR ALUMINIUM RADIATOR

Old part no. : 2547 5010 0182

RADIATOR IN ALUMINIUM MATERIAL FROM M/S TATA TOYO INTRODUCED FOR BETTER COOLING PER-FORMANCE & CORROSION PROPERTIES AGAINST THE EARLIER VERSION OF COPPER BRONZE

Introduced from Sep-2002

New part no. : 2547 5010 0256

BRAKE MASTER CYLINDER

TANDEM MASTER CYLINDER IN ALUMINIUM WITHEPDM SEAL INTRODUCED TO ELIMINATELEAKAGE COMPLAINTS.

Introduced from AUG-2002.

BALL JOINT (LOWER)

NECK DIA INCREASED TO 17 mm FROM 16 mm.

NECK RADIUS CHANGED TO 4 mm AGAINST 2.5 mm.

BALL SEAT MATERIAL IN POLYACETAL INTRODUCEDAGAINST POLYURETHENE.

Introduced from Sep-2000

12


IDLER ARM

OLD PART NO : 2654 3240 0124

PARABOLIC SPRING INTRODUCED IN PLACE OFSEMI ELIPTICAL FOR BETTER RIDE & HANDLING

Introduced from JULY-2003.

NEW PART NO : 2698 3260 0111 (LH)

: 2698 3260 0112 (RH)

DRIVER & CO-DRIVER SEATS

SINGLE PIECE PIN INTRODUCED TO MAINTAINACCURACY IN IDLER ARM BRACKET TO RETAINTOE-IN VALUES & TO ELIMINATE TYRE WEAR.

Introduced from JULY ‘02

LEAF SPRINGSEMI ELIPTICAL

PARABOLIC

INDICA TYPE SEATS WITH WATER REPELLANT SCOTCHGUARD INTRODUCED FOR BETTER COMFORTS &SUPERIOR AESTHETICS.

Introduced from JULY-03.

13


COVER PADDING - DOOR

IMPROVEMENT IN PAINTING QUALITY – SOFT FEEL PAINTING SYSTEM

HEAD LAMP

Old part no. : 2654 7270 0124 (LH)

2654 7270 0125 (RH)

New part no. : 2654 7270 0124 (LH)

2654 7270 0125 (RH)

IMPROVED COVER PADDING MATERIALCHANGED TO ZYLOC FROM ABS AND LUGTHICKNESS INCREASED TO AVOID CRACKING

Introduced from DEC-2002.

SOFT FEEL PAINTING SYSTEM ONDASHBOARD.

Introduced from JULY ‘03

TO PREVENT WATER INGRESS CONTINUOUSGASKET WITH THICKNESS INCREASED FROM 5mm TO 7 mm .

Introduced from JAN-2002

Old part no. : 2659 5441 0161 - RH RHD

2659 5441 0162 - LH RHD

2659 5441 0163 - RH LHD

2659 5441 0164 - LH LHD

New part no. : 2659 5441 0161 - RH RHD

2659 5441 0162 - LH RHD

2659 5441 0163 - RH LHD

2659 5441 0164 - LH LHD

GASKET

14


M/S Z F MAKE PUMP & GEAR BOX INTRODUCED INPLACE OF M/S RANE

1. 90 BAR GEAR BOX WITH IMPORTED SEALS. 2. FULLY ASSEMBLED IMPORTED PUMPS.

Introduced from JULY ‘03.

POWER STEERING PUMP / GEAR BOX

RANE PUMP ZF PUMP

EXHAUST MUFFLERALUMINISED EXHAUST SYSTEMINTRODUCED FOR BETTER CORROSIONRESISTANCE.

Introduced from Sep. 2002.

TATA INDICA TYPE ARMREST,MAGAZINE POCKETS, GRAB

HANDLES

Better passenger comfort & amenities.

NEW LOOK FRONT GRILL

Signifies upgraded version (face lift) with better styling.

15


TATA SAFARI TYPE STEERING WHEEL

Improve look, better grip

NEW LOOK OUTER RVM

Internal adjustment of RVM from inside the vehicle,better convenience to driver, lesser virbations athigh speeds.

SPOILER ON WIPER BLADES

Provided on driver side to improve wiping at highspeeds.

ROOF LAMP AT FRONT FOR CREW CAB

For better illumination in passenger compartment,especially front row.

SAFARI TYPE GEAR SHIFT KNOB

Better look, better grip of gear knob

NEW WHEEL RIM COVERS

Improved look.

16


PIGMENTED FENDERS &REAR CORNER BUMPERS

Better finish / look, eliminates colour fading, longlasting finish.

NEW MOULDED ROOF LINING

Better aesthetics & long lasting.

16" RIMS WITH 205/80 TUBELESS TYRES

To increase ground clearance to 200 mm (from 170mm for 4x2 & 160 mm for 4x4)

DAMPER TUNED SHOCK ABSORBER

Better passenger comfort.

WINDSHIELD GLASS WITH SHADE BAND

Better look / no extra shade band stickers required

CENTRAL LOCKING

Additional feature (100% fitment on face lift vehicle).

17


TORSION BAR SUSPENSION FOR 4X2 ALSO(FACE LIFT VERSION)

Better vehicle stability and ride comfort. Improved tyrelife.

UNDER RUN PROTECTION BUMPER

Mandatory as per CMVR regulation (India) - CentralMotor Vehicle Regulation in India.

ALTERNATOR

Brush material changed from graphite to coppergraphite to minimise wear

RECESSED TYPE TAIL LAMP

Recessed type tail lamp on load body for betteraesthetics.

CATALYTIC CONVERTOR

Inner welding introduced instead of outer side toeliminate breakage complaints.

GEAR BOX - BREATHER

Metallic breather introduced instead of plastic to avoidbreakages & for better breathing

18


OTHER IMPROVEMENTS

Limited slip differential for 4x2 also (100% fitmenton all face lift version)

Excellent traction in difficult terrains.

Oil supply line (turbo charger)

Improved bending to avoid fouling

Turbo boost pressure line

Waste gate hose material & orientation has beenchanged. This would create enough gap from exhaustmanifold to avoid fouling with exhaust manifold.

Oil sump stiffner

Stiffner die corrected to ensure proper flatness toarrest sump gasket leakages.

Clutch housing

Clutch housing mounting dimensions corrected toavoid misalignment of starter motor

Clutch master cylinder

Bore honing & seal in S.B.R. Material introduced toeliminate leakage complaints.

Tie rod

Rubber boot profile modified to avoid fouling with garterspring in the extreme articulation.

Centre link

Ball seat material changed from polyurethene topolyacetal for better wear properties.

IMPROVEMENTS IN CABIN & LOAD BODYNVH Package

Improved noise, vibration & heat resistance pack-age introduced for better passenger comfort.

Door latch HYTRAL coating to reduce noise

Easy & silent operation of doors (opening & closing).

Grey Interiors

Improved look.

New Grey Carpet

Aesthetically better, grey colour matching with otherinteriors.

Load body with bolted hook

Better look, easy to remove if not required, betterstrength.

Fender

Fender beading fixed with 3m tape and adhesive toprevent dislodging

Cover padding - door

Improved cover padding. Material changed to zylocfrom abs and lug thickness increased to avoid cracking

AC control unit

High density pu foam in black colour introducedinplace of cross link foam to improve aesthetics

Cover sill bottom

Mounting arrangement with slots & snap-on buttonchanged to holes & screws for better holding

Rubber- plastics – door inner beading

Corner mould surface match, better trimming at edges,improved low-temperature performance due topresence of baked silicone on surface.

Combi switch

Hazard warning switch housing tightening with screwinstead of snap on type introduced. Silver plate contactintroduced

Tail lamp

Sealing gasket thickness changed from 2 to 6 mm.

Front blinker

Drain hole provided at bottom side.

Tata_TL_WM.pdf

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Transcript of Tata_TL_WM.pdf